Packaging assembly including a particulate trap

ABSTRACT

A sterile packaging assembly configured to receive a surgical instrument is disclosed. The sterile packaging assembly comprises a vacuum-molded tray and a particulate trap. The vacuum-molded tray comprises an instrument cavity configured to receive the surgical instrument, and a trap cavity. The particulate trap is positioned in the trap cavity. The particulate trap comprises a housing including a funnel shaped side terminating in an opening. The opening is in communication with a chamber defined in the particulate trap.

BACKGROUND

The present invention relates to surgical instruments and, in variousarrangements, to surgical stapling and cutting instruments and staplecartridges for use therewith that are designed to staple and cut tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of this invention, and the manner ofattaining them, will become more apparent and the invention itself willbe better understood by reference to the following description ofexemplary embodiments of the invention taken in conjunction with theaccompanying drawings, wherein:

FIG. 1 is a perspective view of a surgical instrument that has aninterchangeable shaft assembly operably coupled thereto;

FIG. 2 is an exploded assembly view of the interchangeable shaftassembly and surgical instrument of FIG. 1;

FIG. 3 is an exploded assembly view of a portion of the surgicalinstrument of FIGS. 1 and 2;

FIG. 4 is another exploded assembly view showing portions of theinterchangeable shaft assembly and surgical instrument of FIGS. 1-3;

FIG. 5 is a perspective view of a staple cartridge positioned in an endeffector of a surgical instrument in accordance with at least oneembodiment, wherein the staple cartridge comprises a plurality of ridgesextending from a cartridge body of the staple cartridge;

FIG. 6 is an exploded view of a battery pack assembly in accordance withat least one embodiment;

FIG. 7 is a perspective view of the battery pack assembly of FIG. 6, asecond battery pack assembly, and a battery dock of a surgicalinstrument;

FIG. 8 is a perspective view of a battery assembly in accordance with atleast one embodiment comprising electrical contacts;

FIG. 9 is a perspective view of a battery pack assembly including thebattery assembly of FIG. 8;

FIG. 10 is a perspective view of the battery pack assembly of FIG. 9positioned in a battery dock of a surgical instrument;

FIG. 11 is a partial perspective view of a surgical instrument inaccordance with at least one embodiment comprising an end effectorincluding a firing member lockout illustrated with components removed;

FIG. 12 is a partial cross-sectional view of the end effector andsurgical instrument of FIG. 11 with the firing member lockout in alocked configuration;

FIG. 13 is a partial cross-sectional view of the end effector andsurgical instrument of FIG. 11 with the firing member lockout in anunlocked configuration;

FIG. 14 is a partial cross-sectional perspective view of a staplecartridge and a cartridge pan attached to the staple cartridge;

FIG. 15 is a partial cross-sectional perspective view of a sledincluding a lockout key of the staple cartridge of FIG. 14;

FIG. 16 is a partial side cross-sectional view of the staple cartridgeof FIG. 14 positioned in an end effector of a surgical instrumentincluding a firing member in a locked out configuration;

FIG. 17 is a partial side cross-sectional view of the end effector ofFIG. 16 depicting the firing member in an unlocked configuration;

FIG. 18 is a perspective view of a manual bailout assembly for use witha drive system of a surgical instrument in accordance with at least oneembodiment;

FIG. 19 is a perspective view of a surgical instrument in accordancewith at least one embodiment comprising an articulation assembly and anarticulation lock assembly illustrated with components removed;

FIG. 20 is a bottom view of the surgical instrument of FIG. 19illustrating the articulation lock assembly in a locked configuration;

FIG. 21 is a bottom view of the surgical instrument of FIG. 19illustrating the articulation lock assembly in an unlockedconfiguration;

FIG. 22 is a perspective view of a control circuit including a conformalcoating in accordance with at least one embodiment;

FIG. 23 is a partial side cross-sectional view of a switch and a seal ofthe control circuit of FIG. 22;

FIG. 24 is a perspective view of seals for use with a gear box and motorof a surgical instrument in accordance with at least one embodiment;

FIG. 25 is a cross sectional view of the seals, gear box, and motor ofFIG. 24;

FIG. 26 is an exploded view of a packaging assembly for a surgicalinstrument illustrating particulate traps positioned in the packagingassembly in accordance with at least one embodiment;

FIG. 27 is a perspective view of a particulate trap;

FIG. 28 is a cross-sectional view of the particulate trap of FIG. 27;

FIG. 29 is a perspective view of a particulate trap;

FIG. 30 is a cross-sectional view of the particulate trap of FIG. 29;

FIG. 31 is a partial perspective view of a staple cartridge including ahoneycomb extension in accordance with at least one embodiment;

FIG. 32 is a partial cross-sectional view of the staple cartridge ofFIG. 31 taken along line 32-32 in FIG. 31;

FIG. 33 is a partial perspective view of a staple cartridge inaccordance with at least one embodiment comprising a plurality of staplecavities defined in a cartridge body and a plurality of posts extendingfrom the cartridge body;

FIG. 34 is an enlarged view of one of the staple cavities and one of theposts of the staple cartridge of FIG. 33;

FIG. 35 is a plan view of one of the staple cavities and a pair of postsof the staple cartridge of FIG. 33;

FIG. 36 is a side cross-sectional view of the staple cavity and posts ofFIG. 35 taken along line 36-36 in FIG. 35;

FIG. 37 is a partial perspective view of a staple cartridge inaccordance with at least one embodiment comprising a plurality of staplecavities defined in a cartridge body and a plurality of quarter-sphereprojections extending from the cartridge body;

FIG. 38 is an enlarged perspective view of one of the staple cavitiesand one of the quarter-sphere projections of the staple cartridge ofFIG. 37;

FIG. 39 is a plan view of one of the staple cavities and aquarter-sphere projection of the staple cartridge of FIG. 37;

FIG. 40 is a side cross-sectional view of the staple cavity andquarter-sphere projection of FIG. 39 taken along line 40-40 in FIG. 39;

FIG. 41 is a partial perspective view of a staple cartridge inaccordance with at least one embodiment comprising a plurality of staplecavities defined in a cartridge body and a plurality of cuboidsextending from the cartridge body;

FIG. 42 is an enlarged perspective view of one of the staple cavitiesand one of the cuboids of the staple cartridge of FIG. 41;

FIG. 43 is a plan view of one of the staple cavities of the staplecartridge of FIG. 41 with a pair of cuboids positioned at the proximaland distal ends of the staple cavity;

FIG. 44 is a side cross-sectional view of the staple cavity and cuboidsof FIG. 43 taken along line 44-44 in FIG. 43;

FIG. 45 is a partial perspective view of a staple cartridge inaccordance with at least one embodiment comprising a plurality of staplecavities defined in a cartridge body and a plurality of posts extendingfrom the cartridge body;

FIG. 46 is an enlarged perspective view of one of the staple cavitiesand a pair of posts of the staple cartridge of FIG. 45;

FIG. 47 is a plan view of one of the staple cavities and a pair of postsof the staple cartridge of FIG. 45;

FIG. 48 is a side cross-sectional view of the staple cavity and posts ofFIG. 47 taken along line 48-48 in FIG. 47;

FIG. 49 is a partial perspective view of a staple cartridge inaccordance with at least one embodiment comprising a plurality of staplecavities defined in a cartridge body and a plurality of posts andcuboids extending from the cartridge body;

FIG. 50 is an enlarged perspective view of one of the staple cavities ofthe staple cartridge of FIG. 49 with a post and a pair of cuboidspositioned adjacent to the staple cavity;

FIG. 51 is a plan view of one of the staple cavities of the staplecartridge of FIG. 49 with a post and a pair of cuboids positioned at theproximal and distal end of the staple cavity;

FIG. 52 is a side cross-sectional view of the staple cavity, posts, andcuboids of FIG. 51 taken along line 52-52 in FIG. 51;

FIG. 53 is a partial perspective view of a staple cartridge inaccordance with at least one embodiment comprising a plurality of staplecavities defined in a cartridge body and a plurality of circular postsand rectangular posts extending from the cartridge body;

FIG. 54 is a plan view of one of the staple cavities of the staplecartridge of FIG. 53 with a post positioned at the proximal end of thestaple cavity and a pair of cuboids positioned at the distal end of thestaple cavity;

FIG. 55 is a side cross-sectional view of the staple cavity, post, andcuboids of FIG. 54 taken along line 55-55 in FIG. 54;

FIG. 56 is a partial perspective view of a staple cartridge inaccordance with at least one embodiment comprising a plurality of staplecavities defined in a cartridge body and a plurality of arcuateprojections extending from the cartridge body;

FIG. 57 is an enlarged perspective view of one of the staple cavitiesand one of the partial cylinder projections of the staple cartridge ofFIG. 56;

FIG. 58 is a plan view of one of the staple cavities of the staplecartridge of FIG. 56 with a pair of partial cylinder projectionspositioned at the proximal and distal ends of the staple cavity;

FIG. 59 is a side cross-sectional view of the staple cavity and partialcylinder projections of FIG. 58 taken along line 59-59 in FIG. 58;

FIG. 60 illustrates a schematic of a surgical instrument including acontrol unit;

FIG. 61 is a side elevation view of a surgical instrument;

FIG. 62 is a partial plan view of an end effector of the surgicalinstrument of FIG. 61 articulated about an articulation axis by anarticulation system;

FIG. 63 is a side elevation view of the surgical instrument of FIG. 61with portions removed to illustrate the articulation system and aclosure system of the surgical instrument; and

FIG. 64 is a side cross-sectional view of a surgical instrumentincluding a manual rotation system and a rotation lockout.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate various embodiments of the invention, in one form, and suchexemplifications are not to be construed as limiting the scope of theinvention in any manner.

DETAILED DESCRIPTION

Applicant of the present application owns the following U.S. PatentApplications that were filed on Jun. 28, 2019 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 16/456,724, entitled SURGICALINSTRUMENT INCLUDING A BATTERY UNIT, now U.S. Patent ApplicationPublication No. 2020/0405292;

U.S. patent application Ser. No. 16/456,746, entitled BATTERY PACKINCLUDING A CIRCUIT INTERRUPTER, now U.S. Patent Application PublicationNo. 2020/0405290;

U.S. patent application Ser. No. 16/456,792, entitled SURGICALINSTRUMENT INCLUDING A FIRING LOCKOUT, now U.S. Patent ApplicationPublication No. 2020/0405308;

U.S. patent application Ser. No. 16/456,744, entitled SURGICALINSTRUMENT INCLUDING A LOCKOUT KEY, now U.S. Patent ApplicationPublication No. 2020/0405305;

U.S. patent application Ser. No. 16/456,781, entitled SURGICALINSTRUMENT INCLUDING A FIRING SYSTEM BAILOUT, now U.S. PatentApplication Publication No. 2020/0405306;

U.S. patent application Ser. No. 16/456,764, entitled SURGICALINSTRUMENT INCLUDING AN ARTICULATION LOCK, now U.S. Patent ApplicationPublication No. 2020/0405294;

U.S. patent application Ser. No. 16/456,785, entitled CONTROL CIRCUITCOMPRISING A COATING, now U.S. Patent Application Publication No.2020/0405307;

U.S. patent application Ser. No. 16/456,765, entitled STAPLE CARTRIDGEINCLUDING A HONEYCOMB EXTENSION, now U.S. Patent Application PublicationNo. 2020/0405309;

U.S. patent application Ser. No. 16/456,783, entitled STAPLE CARTRIDGEINCLUDING PROJECTIONS, now U.S. Patent Application Publication No.2020/0405295; and

U.S. patent application Ser. No. 16/456,734, entitled SURGICALINSTRUMENTS INCLUDING MANUAL AND POWERED SYSTEM LOCKOUTS, now U.S.Patent Application Publication No. 2020/0405293.

Numerous specific details are set forth to provide a thoroughunderstanding of the overall structure, function, manufacture, and useof the embodiments as described in the specification and illustrated inthe accompanying drawings. Well-known operations, components, andelements have not been described in detail so as not to obscure theembodiments described in the specification. The reader will understandthat the embodiments described and illustrated herein are non-limitingexamples, and thus it can be appreciated that the specific structuraland functional details disclosed herein may be representative andillustrative. Variations and changes thereto may be made withoutdeparting from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”), and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a surgicalsystem, device, or apparatus that “comprises,” “has,” “includes”, or“contains” one or more elements possesses those one or more elements,but is not limited to possessing only those one or more elements.Likewise, an element of a system, device, or apparatus that “comprises,”“has,” “includes”, or “contains” one or more features possesses thoseone or more features, but is not limited to possessing only those one ormore features.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” refers to the portion closest to the clinician andthe term “distal” refers to the portion located away from the clinician.It will be further appreciated that, for convenience and clarity,spatial terms such as “vertical”, “horizontal”, “up”, and “down” may beused herein with respect to the drawings. However, surgical instrumentsare used in many orientations and positions, and these terms are notintended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, thereader will readily appreciate that the various methods and devicesdisclosed herein can be used in numerous surgical procedures andapplications including, for example, in connection with open surgicalprocedures. As the present Detailed Description proceeds, the readerwill further appreciate that the various instruments disclosed hereincan be inserted into a body in any way, such as through a naturalorifice, through an incision or puncture hole formed in tissue, etc. Theworking portions or end effector portions of the instruments can beinserted directly into a patient's body or can be inserted through anaccess device that has a working channel through which the end effectorand elongate shaft of a surgical instrument can be advanced.

A surgical stapling system can comprise a shaft and an end effectorextending from the shaft. The end effector comprises a first jaw and asecond jaw. The first jaw comprises a staple cartridge. The staplecartridge is insertable into and removable from the first jaw; however,other embodiments are envisioned in which a staple cartridge is notremovable from, or at least readily replaceable from, the first jaw. Thesecond jaw comprises an anvil configured to deform staples ejected fromthe staple cartridge. The second jaw is pivotable relative to the firstjaw about a closure axis; however, other embodiments are envisioned inwhich the first jaw is pivotable relative to the second jaw. Thesurgical stapling system further comprises an articulation jointconfigured to permit the end effector to be rotated, or articulated,relative to the shaft. The end effector is rotatable about anarticulation axis extending through the articulation joint. Otherembodiments are envisioned which do not include an articulation joint.

The staple cartridge comprises a cartridge body. The cartridge bodyincludes a proximal end, a distal end, and a deck extending between theproximal end and the distal end. In use, the staple cartridge ispositioned on a first side of the tissue to be stapled and the anvil ispositioned on a second side of the tissue. The anvil is moved toward thestaple cartridge to compress and clamp the tissue against the deck.Thereafter, staples removably stored in the cartridge body can bedeployed into the tissue. The cartridge body includes staple cavitiesdefined therein wherein staples are removably stored in the staplecavities. The staple cavities are arranged in six longitudinal rows.Three rows of staple cavities are positioned on a first side of alongitudinal slot and three rows of staple cavities are positioned on asecond side of the longitudinal slot. Other arrangements of staplecavities and staples may be possible.

The staples are supported by staple drivers in the cartridge body. Thedrivers are movable between a first, or unfired position, and a second,or fired, position to eject the staples from the staple cavities. Thedrivers are retained in the cartridge body by a retainer which extendsaround the bottom of the cartridge body and includes resilient membersconfigured to grip the cartridge body and hold the retainer to thecartridge body. The drivers are movable between their unfired positionsand their fired positions by a sled. The sled is movable between aproximal position adjacent the proximal end and a distal positionadjacent the distal end. The sled comprises a plurality of rampedsurfaces configured to slide under the drivers and lift the drivers, andthe staples supported thereon, toward the anvil.

Further to the above, the sled is moved distally by a firing member. Thefiring member is configured to contact the sled and push the sled towardthe distal end. The longitudinal slot defined in the cartridge body isconfigured to receive the firing member. The anvil also includes a slotconfigured to receive the firing member. The firing member furthercomprises a first cam which engages the first jaw and a second cam whichengages the second jaw. As the firing member is advanced distally, thefirst cam and the second cam can control the distance, or tissue gap,between the deck of the staple cartridge and the anvil. The firingmember also comprises a knife configured to incise the tissue capturedintermediate the staple cartridge and the anvil. It is desirable for theknife to be positioned at least partially proximal to the rampedsurfaces such that the staples are ejected ahead of the knife.

FIGS. 1-4 depict a motor-driven surgical cutting and fasteninginstrument 1001. The instrument 1001 includes a housing 1002 thatcomprises a handle 1004 that is configured to be grasped, manipulated,and actuated by a clinician. The housing 1002 is configured to beattached to an interchangeable shaft assembly 1200 including an endeffector 1300 that is configured to perform one or more surgical tasksor procedures. That said, embodiments are envisioned in which the shaftassembly 1200 is not interchangeable with another shaft assembly and is,instead, affixed to, but rotatable relative to, the handle 1004. The endeffector 1300 comprises a surgical cutting and fastening device that isconfigured to operably support a surgical staple cartridge 1304 therein,although any suitable arrangement can be used. The housing 1002 may beadapted for use with robotic systems, instruments, components andmethods such as those disclosed in U.S. patent application Ser. No.13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLEDEPLOYMENT ARRANGEMENTS, now U.S. Patent Application Publication No. US2012/0298719. The disclosure of U.S. patent application Ser. No.13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLEDEPLOYMENT ARRANGEMENTS, now U.S. Patent Application Publication No. US2012/0298719, is incorporated by reference herein in its entirety.

As can be seen in FIG. 3, the handle 1004 comprises handle housingsegments 1006 and 1008 that are interconnected by screws, snap features,and/or adhesives, for example. The handle housing segments 1006, 1008cooperate to form a pistol grip portion 1019 that can be gripped andmanipulated by the clinician, but can comprise any suitableconfiguration. As will be discussed in further detail below, the handle1004 operably supports a plurality of drive systems therein that areconfigured to generate and apply various control motions tocorresponding portions of the interchangeable shaft assembly 1200.

Referring now to FIG. 3, the handle 1004 includes a frame 1022 thatoperably supports a plurality of drive systems. The frame 1022 operablysupports a closure drive system, generally designated as 1003, which isemployed to apply closing and opening motions to the interchangeableshaft assembly 1200. In at least one form, the closure drive system 1003includes an actuator in the form of a closure trigger 1032 that ispivotally supported by the frame 1022. As illustrated in FIG. 3, theclosure trigger 1032 is pivotally coupled to the housing 1002 by a pin1033. Such an arrangement enables the closure trigger 1032 to bemanipulated by a clinician such that, when the clinician grips thepistol grip portion 1019 of the handle 1004, the closure trigger 1032may be easily pivoted from a starting or unactuated position to anactuated position. The closure trigger 1032 may be biased into theunactuated position by a spring or other biasing arrangement. In variousforms, the closure drive system 1003 further includes a closure linkageassembly 1034 that is pivotally coupled to the closure trigger 1032. Ascan be seen in FIG. 3, the closure linkage assembly 1034 includes afirst closure link 1036 and a second closure link 1038 that arepivotally coupled to the closure trigger 1032 by a pin 1035. The secondclosure link 1038 may also be referred to herein as an attachment memberand include a transverse attachment pin 1037.

Still referring to FIG. 3, the first closure link 1036 comprises alocking wall or end 1039 thereon that is configured to cooperate with aclosure release assembly 1007 that is pivotally coupled to the frame1022. In at least one form, the closure release assembly 1007 comprisesa release button assembly 1065 that has a distally protruding lockingpawl 1064 formed thereon. The release button assembly 1065 is pivoted ina counter-clockwise direction by a release spring. As the cliniciandepresses the closure trigger 1032 from its unactuated position towardthe pistol grip portion 1019 of the handle 1004, the first closure link1036 pivots upward to a point wherein the locking pawl 1064 drops intoretaining engagement with the locking wall 1039 on the first closurelink 1036 thereby preventing the closure trigger 1032 from returning tothe unactuated position. Thus, the closure release assembly 1007 servesto lock the closure trigger 1032 in the fully actuated position. Whenthe clinician desires to unlock the closure trigger 1032, the clinicianpivots the closure release button assembly 1065 such that the lockingpawl 1064 is moved out of engagement with the locking wall 1039 on thefirst closure link 1036. When the locking pawl 1064 has been moved outof engagement with the first closure link 1036, the closure trigger 1032may pivot back to the unactuated position. Other closure trigger lockingand release arrangements may also be employed.

Further to the above, an arm 1061 extends from the closure releasebutton 1065. A magnetic element 1063, such as a permanent magnet, forexample, is mounted to the arm 1061. When the closure release button1065 is rotated from its first position to its second position, themagnetic element 1063 moves toward a circuit board 1101. The circuitboard 1101 includes at least one sensor that is configured to detect themovement of the magnetic element 1063. In at least one embodiment, aHall Effect sensor can be mounted to the bottom surface of the circuitboard 1101. The Hall Effect sensor is configured to detect changes in amagnetic field surrounding the Hall Effect sensor caused by the movementof the magnetic element 1063. The Hall Effect sensor is in signalcommunication with a microcontroller, for example, which can determinewhether the closure release button 1065 is in its first position, whichis associated with the unactuated position of the closure trigger 1032,and the open configuration of the end effector 1300, its secondposition, which is associated with the actuated position of the closuretrigger 1032 and the closed configuration of the end effector 1300,and/or any position between the first position and the second position.

In at least one form, the handle 1004 and the frame 1022 operablysupports another drive system, i.e., firing drive system 1080, that isconfigured to apply firing motions to the interchangeable shaft assembly1200. The firing drive system 1080 comprises an electric motor 1082 thatis located in the pistol grip portion 1019 of the handle 1004. Invarious forms, the motor 1082 is be a DC brushed driving motor having amaximum rotation of, approximately, 25,000 RPM, for example. In otherforms, the motor 1082 is a brushless DC motor. In various arrangements,the motor includes a brushless motor, a cordless motor, a synchronousmotor, a stepper motor, or any other suitable electric motor. The motor1082 is powered by a power source 1090 that, in one form, comprises aremovable power pack 1092. As can be seen in FIG. 3, the power pack 1092comprises a proximal housing portion 1094 attached to a distal housingportion 1096. The proximal housing portion 1094 and the distal housingportion 1096 support a plurality of batteries 1098 therein. Batteries1098 may each comprise, for example, a Lithium Ion (“LI”) and/or anyother suitable battery. The distal housing portion 1096 is configured tobe coupled to the circuit board assembly 1101 which is also operablycoupled to the motor 1082. The batteries 1098 may be connected in seriesand/or parallel and comprise the power source for the surgicalinstrument 1001. In addition, the power source 1090 may be replaceableand/or rechargeable.

The electric motor 1082 includes a rotatable shaft that operablyinterfaces with a gear reducer assembly 1084 that is mounted in meshingengagement with a set, or rack, of drive teeth 1129 on alongitudinally-movable drive member 1121. In use, a voltage polarityprovided by the power source 1090 can operate the electric motor 1082 ina clockwise direction. The voltage polarity applied to the electricmotor by the battery can be reversed in order to operate the electricmotor 1082 in a counter-clockwise direction. When the electric motor1082 is rotated in one direction, the drive member 1121 will be axiallydriven in the distal direction DD. When the motor 1082 is driven in theopposite rotary direction, the drive member 1121 will be axially drivenin a proximal direction PD. The handle 1004 includes a switch which canbe configured to reverse the polarity applied to the electric motor 1082by the power source 1090. In other embodiments, the controller of thesurgical instrument 1001 can reverse the polarity applied to theelectric motor 1082 after the staple firing stroke. The handle 1004 canalso include a sensor that is configured to detect the position of thedrive member 1121 and/or the direction in which the drive member 1121 isbeing moved.

The actuation of the motor 1082 is controlled by a firing trigger 1131that is pivotally supported on the handle 1004. The firing trigger 1131may be pivoted between an unactuated position and an actuated position.The firing trigger 1131 is biased into the unactuated position by aspring 1133 or other biasing arrangement such that, when the clinicianreleases the firing trigger 1131, it is pivoted or otherwise returned tothe unactuated position by the spring 1133. In at least one form, thefiring trigger 1131 is positioned “outboard” with respect to the closuretrigger 1032. A firing trigger safety button 1135 is pivotally mountedto the closure trigger 1032 by the pin 1035. The safety button 1135 ispositioned between the firing trigger 1131 and the closure trigger 1032and comprises a pivot arm 1137 protruding therefrom. See FIG. 3. Whenthe closure trigger 1032 is in the unactuated position, the safetybutton 1135 is contained in the handle 1004 where the clinician cannotreadily access it and move it between a safety position preventingactuation of the firing trigger 1131 and a firing position wherein thefiring trigger 1131 may be fired. As the clinician depresses the closuretrigger 1032, the safety button 1135 and the firing trigger 1131 pivotdown wherein they can then be manipulated by the clinician.

As indicated above, the longitudinally movable drive member 1121 has arack of teeth 1129 formed thereon for meshing engagement with acorresponding drive gear 1086 of the gear reducer assembly 1084. Thesurgical instrument 1001 also includes a manually-actuatable “bailout”assembly 1141 that is configured to enable the clinician to manuallyretract the longitudinally movable drive member 1121 should the motor1082 become disabled. The bailout assembly 1141 includes a lever orbailout handle assembly 1143 that is configured to be manually pivotedinto ratcheting engagement with teeth 1124 also provided in the drivemember 1121. Thus, the clinician can manually retract the drive member1121 by using the bailout handle assembly 1143 to ratchet the drivemember 1121 in the proximal direction PD. U.S. Patent ApplicationPublication No. US 2010/0089970, now U.S. Pat. No. 8,608,045, disclosesbailout arrangements and other components, arrangements and systems thatmay also be employed with the various instruments disclosed herein. U.S.patent application Ser. No. 12/249,117, entitled POWERED SURGICALCUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM,now U.S. Pat. No. 8,608,045, is hereby incorporated by reference hereinin its entirety. U.S. patent application Ser. No. 12/235,972, entitledMOTORIZED SURGICAL INSTRUMENT, now U.S. Pat. No. 9,050,083, is herebyincorporated by reference herein in its entirety. U.S. patentapplication Ser. No. 11/651,807, entitled SURGICAL INSTRUMENT WITHWIRELESS COMMUNICATION BETWEEN CONTROL UNIT AND REMOTE SENSOR, now U.S.Pat. No. 8,459,520, is hereby incorporated by reference herein in itsentirety.

Further to the above, turning now to FIGS. 2 and 4, the end effector1300 comprises an elongate channel 1302 that is configured to operablysupport the staple cartridge 1304 therein. The end effector 1300 furtherincludes an anvil 1306 that is pivotally supported relative to theelongate channel 1302. The interchangeable shaft assembly 1200 mayfurther include an articulation joint 1270 and an articulation lockwhich can be configured to releasably hold the end effector 1300 in adesired position relative to a shaft axis SA (FIG. 4). Details regardingthe construction and operation of the end effector 1300, thearticulation joint 1270 and the articulation lock are set forth in U.S.patent application Ser. No. 13/803,086, filed Mar. 14, 2013, entitledARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK. Theentire disclosure of U.S. patent application Ser. No. 13/803,086, filedMar. 14, 2013, entitled ARTICULATABLE SURGICAL INSTRUMENT COMPRISING ANARTICULATION LOCK is hereby incorporated by reference herein in itsentirety. Other embodiments are envisioned with more than onearticulation joint or no articulation joint,

As can be seen in FIG. 4, the interchangeable shaft assembly 1200further includes a proximal housing or nozzle 1201 comprised of nozzleportions 1202 and 1203. The interchangeable shaft assembly 1200 canfurther include a closure tube 1260 which can be utilized to closeand/or open the anvil 1306 of the end effector 1300. The shaft assembly1200 includes a spine 1210 that is configured to, one, slideably supporta firing member therein and, two, slideably support the closure tube1260 which extends around the spine 1210. The spine 1210 can also beconfigured to slideably support a proximal articulation driver. Thearticulation driver has a distal end that is configured to operablyengage the articulation lock. The articulation lock interfaces with anarticulation frame that is adapted to operably engage a drive pin on theend effector frame. As indicated above, further details regarding theoperation of the articulation lock and the articulation frame may befound in U.S. patent application Ser. No. 13/803,086. In variouscircumstances, the spine 1210 can comprise a proximal end 1211 which isrotatably supported in a chassis 1240. The proximal end 1211 of thespine 1210 has a thread 1214 formed thereon for threaded attachment to aspine bearing 1216 configured to be supported within the chassis 1240.See FIG. 4. Such an arrangement facilitates the rotatable attachment ofthe spine 1210 to the chassis 1240 such that the spine 1210 may beselectively rotated about the shaft axis SA relative to the chassis1240.

Referring primarily to FIG. 4, the interchangeable shaft assembly 1200includes a closure shuttle 1250 that is slideably supported within thechassis 1240 such that it may be axially moved relative thereto. Theclosure shuttle 1250 includes a pair of proximally-protruding hooks 1252that are configured for attachment to the attachment pin 1037 (FIGS. 2and 3) that is attached to the second closure link 1038 as will bediscussed in further detail below. A proximal end 1261 of the closuretube 1260 is coupled to the closure shuttle 1250. More specifically, aU-shaped connector 1263 is inserted into an annular slot 1262 in theproximal end 1261 of the closure tube 1260 and is retained withinvertical slots 1253 in the closure shuttle 1250. Such an arrangementserves to attach the closure tube 1260 to the closure shuttle 1250 foraxial travel therewith while enabling the closure tube 1260 to rotaterelative to the closure shuttle 1250 about the shaft axis SA. A closurespring 1268 is journaled on the closure tube 1260 and serves to bias theclosure tube 1260 in the proximal direction PD which can serve to pivotthe closure trigger into the unactuated position when the shaft assembly1200 is operably coupled to the handle 1004.

Further to the above, the interchangeable shaft assembly 1200 includesan articulation joint 1270. As can be seen in FIG. 4, the articulationjoint 1270 includes a double pivot closure sleeve assembly 1271. Thedouble pivot closure sleeve assembly 1271 includes an end effectorclosure sleeve assembly 1272 having upper and lower distally projectingtangs 1273, 1274. An end effector closure sleeve assembly 1272 includesa horseshoe aperture 1275 and a tab 1276 for engaging an opening tab onthe anvil 1306 in the various manners described in U.S. patentapplication Ser. No. 13/803,086, filed Mar. 14, 2013, entitled,ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK whichhas been incorporated by reference herein. The horseshoe aperture 1275and tab 1276 engage a tab on the anvil when the anvil 1306 is opened. Anupper double pivot link 1277 includes upwardly projecting distal andproximal pivot pins that engage, respectively, an upper distal pin holein the upper proximally projecting tang 1273 and an upper proximal pinhole in an upper distally projecting tang 1264 on the closure tube 1260.A lower double pivot link 1278 includes upwardly projecting distal andproximal pivot pins that engage, respectively, a lower distal pin holein the lower proximally projecting tang 1274 and a lower proximal pinhole in the lower distally projecting tang 1265. See also FIG. 4.

During an actuation of the closing system, the closure tube 1260 istranslated distally (direction DD) to close the anvil 1306 in responseto the actuation of the closure trigger 1032. The anvil 1306 is closedby distally translating the closure tube 1260 and thus the closuresleeve assembly 1272, causing it to strike a proximal surface on theanvil 1360 in the manner described in the aforementioned referenced U.S.patent application Ser. No. 13/803,086. As was also described in detailin that reference, the anvil 1306 is opened by proximally translatingthe closure tube 1260 and the closure sleeve assembly 1272, causing tab1276 and the horseshoe aperture 1275 to contact and push against theanvil tab to lift the anvil 1306.

As discussed above, the interchangeable shaft assembly 1200 furtherincludes a firing member that is supported for axial travel within theshaft spine 1210. The firing member includes an intermediate firingshaft portion 1222 attached to a distal cutting portion or knife bar.The intermediate firing shaft portion 1222 includes a longitudinal slotin the distal end thereof which receives a tab on the proximal end ofthe distal knife bar. The longitudinal slot and the proximal end aresized and configured to permit relative movement therebetween and cancomprise a slip joint. The slip joint can permit the intermediate firingshaft portion 1222 of the firing drive to be moved to articulate the endeffector 1300 without moving, or at least substantially moving, theknife bar. Once the end effector 1300 has been suitably oriented, theintermediate firing shaft portion 1222 can be advanced distally until aproximal sidewall of the longitudinal slot comes into contact with thetab in order to advance the knife bar and fire the staple cartridgepositioned within the channel 1302. Further description of the operationof the firing member may be found in U.S. patent application Ser. No.13/803,086.

As can be seen in FIG. 4, the shaft assembly 1200 further includes aswitch drum 1500 that is rotatably received on the closure tube 1260.The switch drum 1500 comprises a hollow shaft segment 1502 that has ashaft boss formed thereon to receive an outwardly protruding actuationpin therein. In various circumstances, the actuation pin extends througha longitudinal slot provided in a lock sleeve to facilitate axialmovement of the lock sleeve when it is engaged with the articulationdriver. A rotary torsion spring 1420 is configured to engage the boss onthe switch drum 1500 and a portion of the nozzle 1201 to apply a biasingforce to the switch drum 1500. The switch drum 1500 further comprisescircumferential openings or slots 1506 defined therein which can beconfigured to receive circumferential mounts extending from the nozzlehalves 1202, 1203 and permit relative rotation, but not translation,between the switch drum 1500 and the proximal nozzle 1201. The mountsalso extend through openings 1266 in the closure tube 1260 to be seatedin recesses in the shaft spine 1210. U.S. patent application Ser. No.13/803,086 and U.S. patent application Ser. No. 14/226,142, entitledSURGICAL INSTRUMENT COMPRISING A SENSOR SYSTEM, filed Mar. 26, 2014, isincorporated by reference herein in its entirety.

As also illustrated in FIG. 4, the shaft assembly 1200 comprises a slipring assembly 1600 which is configured to conduct electrical power toand/or from the end effector 1300 and/or communicate signals to and/orfrom the end effector 1300, for example. The slip ring assembly 1600comprises a proximal connector flange 1604 that is mounted to a chassisflange 1242 that extends from the chassis 1240 and a distal connectorflange that is positioned within a slot defined in the shaft housings.The proximal connector flange 1604 comprises a first face and the distalconnector flange comprises a second face which is positioned adjacent toand movable relative to the first face. The distal connector flange canrotate relative to the proximal connector flange 1604 about the shaftaxis SA. The proximal connector flange 1604 comprises a plurality ofconcentric, or at least substantially concentric, conductors defined inthe first face thereof. A connector is mounted on the proximal side ofthe connector flange and has a plurality of contacts, wherein eachcontact corresponds to and is in electrical contact with one of theconductors. Such an arrangement permits relative rotation between theproximal connector flange 1604 and the distal connector flange whilemaintaining electrical contact therebetween. The proximal connectorflange 1604 includes an electrical connector 1606 which places theconductors in signal communication with a shaft circuit board 1610mounted to the shaft chassis 1240. In at least one instance, a wiringharness comprising a plurality of conductors extends between theelectrical connector 1606 and the shaft circuit board 1610. Theelectrical connector 1606 extends proximally through a connector opening1243 defined in the chassis mounting flange 1242. See FIG. 4. U.S.patent application Ser. No. 13/800,067, entitled STAPLE CARTRIDGE TISSUETHICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, is incorporated byreference herein in its entirety. U.S. patent application Ser. No.13/800,025, entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM,filed on Mar. 13, 2013, is incorporated by reference herein in itsentirety. Further details regarding slip ring assembly 1600 may be foundin U.S. patent application Ser. No. 13/803,086.

As discussed above, the shaft assembly 1200 can include a proximalportion which is fixably mounted to the handle 1004 and a distal portionwhich is rotatable about a longitudinal axis. The rotatable distal shaftportion can be rotated relative to the proximal portion about the slipring assembly 1600, as discussed above. The distal connector flange ofthe slip ring assembly 1600 is positioned within the rotatable distalshaft portion. Moreover, further to the above, the switch drum 1500 isalso positioned within the rotatable distal shaft portion. When therotatable distal shaft portion is rotated, the distal connector flangeand the switch drum 1500 can be rotated synchronously with one another.In addition, the switch drum 1500 is rotatable between a first positionand a second position relative to the distal connector flange. When theswitch drum 1500 is in its first position, the articulation drive systemis operably disengaged from the firing drive system 1080 and, thus, theoperation of the firing drive system 1080 does not articulate the endeffector 1300 of the shaft assembly 1200. When the switch drum 1500 isin its second position, the articulation drive system is operablyengaged with the firing drive system 1080 and, thus, the operation ofthe firing drive system 1080 articulates the end effector 1300 of theshaft assembly 1200. When the switch drum 1500 is moved between itsfirst position and its second position, the switch drum 1500 is movedrelative to distal connector flange. In various instances, the shaftassembly 1200 can comprise at least one sensor configured to detect theposition of the switch drum 1500.

Referring again to FIG. 4, the chassis 1240 includes two taperedattachment portions 1244 formed thereon that are adapted to be receivedwithin corresponding dovetail slots 1702 formed within a distalattachment flange portion 1700 of the frame 1022. See FIG. 3. Eachdovetail slot 1702 is tapered or, stated another way, somewhat V-shapedto seatingly receive the attachment portions 1244 therein. As can befurther seen in FIG. 4, a shaft attachment lug 1226 is formed on theproximal end of the intermediate firing shaft 1222. When theinterchangeable shaft assembly 1200 is coupled to the handle 1004, theshaft attachment lug 1226 is received in a firing shaft attachmentcradle 1126 formed in the distal end 1125 of the longitudinal drivemember 1121. See FIG. 3.

The surgical instrument 1001 comprises a latch system 1710 for removablycoupling the shaft assembly 1200 to the housing 1002 and, morespecifically, to the frame 1022. As can be seen in FIG. 4, the latchsystem 1710 includes a lock member or lock yoke 1712 that is movablycoupled to the chassis 1240. The lock yoke 1712 has a U-shape with twospaced downwardly extending legs 1714. The legs 1714 each have a pivotlug 1715 formed thereon that are adapted to be received in correspondingholes 1245 formed in the chassis 1240. Such an arrangement facilitatesthe pivotal attachment of the lock yoke 1712 to the chassis 1240. Thelock yoke 1712 includes two proximally protruding lock lugs 1716 thatare configured for releasable engagement with corresponding lock detentsor grooves 1704 in the distal attachment flange 1700 of the frame 1022.See FIG. 3. The lock yoke 1712 is biased in the proximal direction byspring or biasing member. Actuation of the lock yoke 1712 isaccomplished by a latch button 1722 that is slideably mounted on a latchactuator assembly 1720 that is mounted to the chassis 1240. The latchbutton 1722 is biased in a proximal direction relative to the lock yoke1712. As will be discussed in further detail below, the lock yoke 1712is moved to an unlocked position by biasing the latch button 1722 in thedistal direction which also causes the lock yoke 1712 to pivot out ofretaining engagement with the distal attachment flange 1700 of the frame1022. When the lock yoke 1712 is in retaining engagement with the distalattachment flange 1700 of the frame 1022, the lock lugs 1716 areretainingly seated within the corresponding lock detents or grooves 1704in the distal attachment flange 1700.

In use, in various instances, the clinician may partially actuate theclosure trigger 1032 to grasp and manipulate the target tissue into adesired position. Once the target tissue is suitably positioned withinthe end effector 1300, the clinician may then fully actuate the closuretrigger 1032 to close the anvil 1306 and clamp the target tissue inposition for cutting and stapling. In that instance, the closure drivesystem 1003 has been fully actuated. After the target tissue has beenclamped in the end effector 1300, it may be desirable to prevent theinadvertent detachment of the shaft assembly 1200 from the housing 1002.The latch system 1710 is configured to prevent such inadvertentdetachment. Referring to FIG. 4, the lock yoke 1712 includes two lockhooks 1718 that are adapted to contact corresponding lock lug portions1256 that are formed on the closure shuttle 1250. When the closureshuttle 1250 is in an unactuated position (i.e., the closure system 1003is unactuated and the anvil 1306 is open), the lock yoke 1712 may bepivoted in a distal direction to unlock the interchangeable shaftassembly 1200 from the housing 1002. In such instances, the lock hooks1718 do not contact the lock lug portions 1256 on the closure shuttle1250. However, when the closure shuttle 1250 is moved to an actuatedposition (i.e., the closure drive system 1003 is actuated and the anvil1306 is in the closed position), the lock yoke 1712 is prevented frombeing pivoted to an unlocked position. Stated another way, if theclinician were to attempt to pivot the lock yoke 1712 to an unlockedposition or the lock yoke 1712 was inadvertently bumped or contacted ina manner that might otherwise cause it to pivot distally, the lock hooks1718 on the lock yoke 1712 will contact the lock lugs 1256 on theclosure shuttle 1250 and prevent movement of the lock yoke 1712 to anunlocked position.

In order to assemble the interchangeable shaft assembly 1200 to thehandle 1004, the clinician may position the chassis 1240 of theinterchangeable shaft assembly 1200 above or adjacent to the distalattachment flange 1700 of the frame 1022 such that the taperedattachment portions 1244 formed on the chassis 1240 are aligned with thedovetail slots 1702 in the frame 1022. The clinician may then move theshaft assembly 1200 along an installation axis that is perpendicular tothe shaft axis SA to seat the attachment portions 1244 in operableengagement with the corresponding dovetail receiving slots 1702. Indoing so, the shaft attachment lug 1226 on the intermediate firing shaft1222 will also be seated in the cradle 1126 in the longitudinallymovable drive member 1121 and the portions of pin 1037 on the secondclosure link 1038 will be seated in the corresponding hooks 1252 in theclosure shuttle 1250. As used herein, the term operable engagement inthe context of two components means that the two components aresufficiently engaged with each other so that upon application of anactuation motion thereto, the components may carry out their intendedaction, function and/or procedure.

At least five systems of the interchangeable shaft assembly 1200 can beoperably coupled with at least five corresponding systems of the handle1004. A first system can comprise a frame system which couples and/oraligns the frame or spine of the shaft assembly 1200 with the frame 1022of the handle 1004. Another system can comprise a closure drive system1003 which operably connect the closure trigger 1032 of the handle 1004and the closure tube 1260 and the anvil 1306 of the shaft assembly 1200.As outlined above, the closure shuttle 1250 of the shaft assembly 1200is engaged with the pin 1037 on the second closure link 1038. Anothersystem can comprise the firing drive system 1080 which operably connectsthe firing trigger 1131 of the handle 1004 with the intermediate firingshaft 1222 of the shaft assembly 1200. As outlined above, the shaftattachment lug 1226 is operably connected with the cradle 1126 of thelongitudinal drive member 1121. Another system can comprise anelectrical system which can signal to a controller in the handle 1004,such as a microcontroller, for example, that a shaft assembly, such asshaft assembly 1200, for example, has been operably engaged with thehandle 1004 and/or, two, conduct power and/or communicate signalsbetween the shaft assembly 1200 and the handle 1004. Further to theabove, the shaft assembly 1200 can include an electrical connector 1810that is operably mounted to the shaft circuit board 1610. The electricalconnector 1810 is configured for mating engagement with a correspondingelectrical connector 1800 on the handle control board 1101. Furtherdetails regaining the circuitry and control systems may be found in U.S.patent application Ser. No. 13/803,086, and U.S. patent application Ser.No. 14/226,142, the entire disclosures of which are hereby incorporatedherein by reference in their entirety. The fifth system may comprise thelatching system for releasably locking the shaft assembly 1200 to thehandle 1004.

An end effector of a surgical stapling instrument is illustrated in FIG.5. The end effector includes an anvil, such as an anvil 2001, forexample, and a jaw, or staple cartridge channel, 2002 configured toremovably support a staple cartridge therein. A staple cartridge 2000,for example, is positioned in the cartridge channel 2002. The staplecartridge 2000 comprises a cartridge body 2010 including a plurality ofstaple cavities 2050 defined therein. A staple is removably stored ineach staple cavity 2050. The cartridge body 2010 includes a deck surface2011 and a longitudinal slot 2015 defined in the deck surface 2011configured to receive a firing member and/or cutting edge therein. Thecartridge body 2010 further comprises a distal end 2013, a proximal end2016, and opposing longitudinal sides 2012 extending between the distalend 2013 and the proximal end 2016. The entire disclosure of U.S. patentapplication Ser. No. 14/319,004, entitled SURGICAL END EFFECTORS WITHFIRING ELEMENT MONITORING ARRANGEMENTS, now U.S. Pat. No. 9,844,369, ishereby incorporated by reference herein in its entirety.

FIGS. 6 and 7 illustrate an embodiment of a battery unit 110 for usewith a surgical instrument 100. A handle 102 of the surgical instrument100 houses at least one battery unit 110. The battery unit 110 compriseone or more batteries 112 arranged in a series and/or parallelconfiguration. At least one of the batteries 112 may be rechargeable.The batteries may be CR-123A batteries and/or CR-2 batteries and/or anyother suitable battery, for example. The handle 102 of the surgicalinstrument 100 comprises a battery dock 104 to which the battery unit110 is attached. The battery dock 104 comprises any suitable structurefor coupling the battery unit 110 to the instrument 100. For example,the battery dock 104 comprises a cavity in the handle 102 configured toreceive at least a portion of the battery unit 110, as illustrated inFIG. 7. In other embodiments, the battery dock 104 may be implementedusing any suitable structures. In one embodiment, the battery dock 104includes a post 106 that is received by the battery unit 110. In oneembodiment, a pistol grip portion of the handle 102 comprises thebattery dock 104.

As discussed in greater detail below, the battery dock 104 comprise aprotruding portion which interacts with the battery unit 110 when thebattery unit 110 is attached to the handle 102. Once attached, thebattery unit 110 is electrically connected to and may provide power to acircuit of the surgical instrument 100. The circuit may be located inthe handle 102, in an end effector of the surgical instrument 100,and/or in any combination of locations within the instrument 100. Inuse, the circuit may power the operation of at least one surgicalimplement at the end effector. For example, the circuit comprises anelectric motor for operating an electrically-powered cutter, clasper,and/or other mechanical device. In addition to, or instead of, a motor,the circuit may comprise suitable circuit components for implementing anRF, ultrasonic, and/or other type of non-motor-powered surgicalimplement, for example.

Referring again to FIGS. 6 and 7, the battery unit 110 comprises abattery housing 114, batteries 112 positioned in the battery housing114, and an outer housing 120 configured to receive the battery housing114. In the illustrated embodiment, the battery housing 114 isconfigured to store four batteries 112; however, other embodiments areenvisioned where the battery housing 114 stores any suitable numberand/or type of batteries 112. For example, CR123 and/or CR2 batterycells may be used. The outer housing 120 comprises a top cover or lid122 movable between an open position (FIG. 6) and a closed position. Thelid 122 is secured in the closed position by a retention member 123 thatengages a recess 129 in the outer housing 120. Other embodiments areenvisioned with different securement methods such as latches, detents,etc. to secure the lid 122 to the outer housing 120. The outer housing120 further includes a post 124 including electrical contacts 126positioned thereon. The battery housing 114 comprises a cavity 118 andelectrical contacts 116. The electrical contacts 116 and electricalcontacts 126 provide a portion of an electrical pathway from thebatteries 112 to the surgical instrument 100 as will be discussed ingreater detail below.

When the battery housing 114 is positioned in the outer housing 120, thepost 124 of the outer housing 120 is received in the cavity 118 of thebattery housing 114 and the electrical contacts 116 of the batteryhousing 114 are in contact with the electrical contacts 126 of the outerhousing 120. The lid 122 is then closed to enclose the battery housing114 within the outer housing 120. In at least one embodiment, the outerhousing 120 may be a sterile outer housing 120 that has gone through asterilization procedure such as autoclaving, for example. That said, thebattery housing 114 and batteries 112 received therein may be sterile,but do not have to be. Thus, when the non-sterile battery assembly isreceived in the sterile outer housing 120 the entire battery unit 110becomes a sterile assembly. In other words, the outer housing 120 actsas a sterile barrier between the non-sterile battery housing 114 andbatteries 112 and the surrounding environment. Such an arrangementallows battery assemblies such as the battery housing 114 to be re-usedwithout having to be sterilized. In at least one embodiment, a seal ispositioned between the lid 122 and the outer housing 120 to seal thebattery housing 114 and batteries 112 from the surrounding environment.The seal may be rubber, plastic, and/or any suitable material.

After the batteries 112 are assembled to the battery housing 114 and thebattery housing 114 is assembled to the outer housing 120, the batteryunit 110 is attached to the surgical instrument 100. The battery unit110 comprises a cavity defined inside the post 124 of the outer housing120. This cavity defined within the post 124 is configured to receivethe post 106 of the battery dock 104 of the surgical instrument 100. Theelectrical contacts 126 positioned on the post 124 of the outer housing120 are aligned with and in electrical contact with electrical contacts108 positioned in the battery dock 104 when the battery unit 110 isseated in the battery dock 104. The electrical contacts 126 are sealedsuch that the sterile barrier discussed above remains intact. When thebattery unit 110 is assembled within the battery dock 104, theelectrical contacts 116, 126, and 108 form an electrical pathway fromthe batteries 112 to the surgical instrument 100.

Referring to FIG. 7, the battery unit 110 comprises exterior dimensionssimilar to that of a battery unit 130 and/or those described in U.S.Pat. No. 8,632,525, entitled POWER CONTROL ARRANGEMENTS FOR SURGICALINSTRUMENTS AND BATTERIES, the entire disclosure of which is herebyincorporated herein by reference in its entirety. The battery dock 104of the surgical instrument 100 can receive either the battery unit 110or the battery unit 130.

Further to the above, the battery housing 114 further comprises acontrol circuit or circuit board 113 and battery status indicators 119in communication with the circuit board 113 and the batteries 112 whenthe batteries 112 are positioned in the battery housing 114. The batterystatus indicators 119 comprise lights; however, other embodiments withdifferent types of indicators 119 are envisioned. In at least oneembodiment the status indicators 119 comprise a linear LED displayand/or a rotary dial LED indicator, for example. The lid 122 of theouter housing 120 comprises a clear window 128 aligned with the batterystatus indicators 119 when the lid 122 is closed. The clear window 128allows a clinician to see the status indicators 119 after the batteryhousing 114 is assembled within the outer housing 120. In alternativeembodiments, the lid 122 comprises the status indicators 119.

Further to the above, the battery status indicators 119 are configuredto indicate the charging status of the battery unit 110, for example. Inat least one embodiment, the battery status indicators 119 indicate theremaining electrical capacity of the battery unit 110 as a number ofremaining actuations of the surgical instrument 100. The actuationscould be the number of staple cartridges that could still be firedbefore having to replace the battery unit 110, for example. Theremaining electrical capacity may be displayed as the amount of timeuntil the battery unit 110 is drained if the battery unit 110 isdischarged at a predetermined, or recent, voltage, current, and/or powerlevel, for example. Further still, the control circuit 113 of thebattery housing 114 is configured to limit the current draw of thesurgical instrument 100 in at least one embodiment in order to extendthe life of a battery unit 110 to complete a staple firing, for example.For instance, if the battery unit 110 has enough power to complete twoand a half more staple firings based on historical data, the chargemanagement circuit of the battery unit 110 can limit the current draw toexpedite life to three firings.

FIGS. 8-10 illustrate a battery unit 210 for use with a surgicalinstrument such as the surgical instrument 100, for example. Similar tobattery unit 110 discussed above, the battery unit 210 is configured tobe received in the battery dock 104 of the surgical instrument 100. Thebattery unit 201 comprises a battery assembly 214 and an outer housing220 configured to receive the battery assembly 214. The battery assembly214 comprises four batteries 112, however other embodiments areenvisioned where the battery assembly 214 comprises two batteries, threebatteries, or more than four batteries. The battery assembly 214comprises electrical contacts 216 which electrically connect thebatteries 112 into two pairs. The battery assembly 214 further comprisesa first electrical connector 218 extending from the first pair ofbatteries 112 and a second electrical connector 219 extending from thesecond pair of batteries 112. The first and second electrical connectors218, 219 are configured to electrically connect the two pairs ofbatteries 112. A dielectric interruption member or pull tab 230 ispositioned between the first and second electrical connectors 218, 219such that the two pairs of batteries 112 are not electrically connectedwhen the pull tab 230 is present. As a result, the battery circuit isopen when the pull tab 230 is present.

The electrical contacts 216, the first electrical connector 218, and thesecond electrical connector 219 are soldered, for example, to thebatteries 112. The first and second electrical connectors 218, 219 arebiased toward one another by a biasing member, such as a leaf spring forexample, and/or by their own compliant structure. Other embodiments areenvisioned where the electrical contacts 216, the first electricalconnector 218, and the second electrical connector 219 are part of anouter housing or casing that houses the batteries 112. When thebatteries are positioned in the outer housing or casing they are broughtinto contact with, or cam med into, the electrical contacts 216, thefirst electrical connector 218, and the second electrical connector 219.In other embodiments, one or more of the contacts 216 are cammed into aclosed position to close at least portions of the battery circuit. Thatsaid, the battery circuit is not completely closed until the batteryunit 210 is seated in the battery dock 104. In at least one embodiment,the outer housing 220 comprises the electrical contacts 216, the firstelectrical connector 218, and the second electrical connector 219, forexample.

As discussed above, the outer housing 220 is configured to receive thebattery assembly 214. Once the battery assembly 214 is received in theouter housing 220, a covering or lid 222 may be closed to enclose thebattery assembly 214 within the outer housing 220. The outer housing 220and lid 222 form a sterile barrier between the battery assembly 214 andthe surrounding environment as was discussed above with regard to theembodiment of FIGS. 6 and 7. The outer housing 220 further comprises aretention member 223 similar to retention member 123. The retentionmember 223 secures the lid 222 to the outer housing 220, for example.

Further to the above, the pull tab 230 is accessible to a user of thebattery unit 210 when the battery assembly 214 is positioned in theouter housing 220 and when the battery unit 210 is attached to thesurgical instrument 100. The pull tab 230 can be displaced toelectrically connect all four batteries 112 within the battery assembly214. The pull tab 230 can be displaced before or after the battery unit210 is assembled to the surgical instrument 100. In at least oneembodiment, the battery unit 110 comprises packaging that at leastpartially surrounds the battery unit 210. The packaging may be attachedto the pull tab 230 such that, when the battery unit 210 is at leastpartially removed from the packaging, the pull tab 230 is pulled out ofthe battery unit 210 allowing the four batteries 112 to be electricallyconnected. In at least one embodiment, the electrical connection betweenthe two pairs of batteries 212 via the first and second electricalconnectors 218, 219 is interrupted again when the battery unit 210 isdetached from the surgical instrument 100, for example. Morespecifically, the battery unit 210 comprises a resettable pull tab thatis biased toward or spring loaded toward the battery assembly 214 suchthat when the battery unit 210 is detached from the battery dock 104,the resettable tab interrupts the electrical connection between the twopairs of batteries 212.

An end effector 320 of a surgical instrument, such as a surgicalinstrument 300, is illustrated in FIGS. 11-13. The surgical instrument300 may be similar to the surgical instruments described herein. The endeffector 320 comprises a first jaw, or elongate channel 330, and asecond jaw, or anvil 340. The anvil 340 is pivotally coupled to theelongate channel 330 and movable relative to the elongate channel 330between an open position and a closed position. However, otherembodiments are envisioned wherein the elongate channel 330 is movablerelative to the anvil 340 between an open position and a closedposition. In any event, the elongate channel 330 is configured toreceive a staple cartridge 350. The staple cartridge 350 is replaceablewith another staple cartridge; however, other embodiments are envisionedin which the staple cartridge is not replaceable. The staple cartridge350 comprises a plurality of staples removably stored therein. Thestaples are prevented from falling out of the staple cartridge 350 by acartridge pan 352 that is attached to the staple cartridge 350. Further,the staple cartridge 350 comprises a sled 354 configured to move from aproximal unfired position to a distal fired position to eject thestaples from the staple cartridge 350 during a staple firing stroke.

Further to the above, the elongate channel 330 comprises a longitudinalcavity 332 and a channel opening 334 defined in the bottom of theelongate channel 330. The surgical instrument 300 further comprises afiring member 310 configured to travel through the end effector 320during a staple firing stroke to eject the staples from the staplecartridge 350. More specifically, the firing member 310 is configured tomove the sled 354 from the proximal unfired position toward the distalfired position during the staple firing stroke to eject the staples fromthe staple cartridge 350. The firing member 310 comprises a lowerlateral flange, or first camming member, 312 and an upper lateralflange, or second camming member, 314. During the staple firing stroke,the first camming member 312 is configured to slide within thelongitudinal cavity 332 defined in the elongate channel 330 and thesecond camming member 314 is configured to slideably engage an anvilslot 342 defined in the anvil 340 to position the anvil 340 at a desiredspacing relative to the elongate channel 330 and the staple cartridge350. The firing member 310 further comprises a distal portion, or distalprotrusion, 316 which, in conjunction with the sled 354, overcomes afiring member lockout as described in greater detail below.

When a staple cartridge 350 is not positioned in the elongate channel330 or when the staple cartridge 350 is positioned in the elongatechannel 330 and the sled 354 is not in the proximal unfired position atthe beginning of the staple firing stroke, the firing member 310 islocked out (i.e., prevented from performing the staple firing stroke).More specifically, if the staple cartridge 350 is not positioned in theelongate channel 330 and the firing member 310 is actuated (i.e.,advanced distally), the first camming member 312 of the firing member310 will be biased into the channel opening 334 in the elongate channel330 at the beginning of the staple firing stroke. The firing member 310is biased toward the channel opening 334 by a biasing member such as aspring, for example, in the shaft of the surgical instrument 300. Whenthe first camming member 312 is positioned in the channel opening 334,the first camming member 312 engages a sidewall or lock shoulder 336 ofthe channel opening 334 at the beginning of the staple firing strokethereby preventing further distal advancement of the firing member 310.If the staple cartridge 350 is positioned in the elongate channel 330and the sled 354 is not in the proximal unfired position as shown inFIG. 12, the same result happens as if the staple cartridge 350 ismissing altogether.

In order to defeat the firing member lockout describe above, referringprimarily to FIG. 13, the sled 354 must be in the proximal unfiredposition when the staple cartridge 350 is positioned in the elongatechannel 330. The sled 354 comprises a proximal camming surface 356 thatcammingly engages the distal protrusion 316 upwardly when the firingmember 310 is advanced distally and lifts the firing member 310 over thelock shoulder 336 to permit the firing member 310 to perform the staplefiring stroke. Further, the interaction between the distal protrusion316 and the proximal camming surface 356 aligns the first camming member312 with the longitudinal cavity 332 of the elongate channel 330 andaligns the second camming member 314 with the anvil slot 342 of theanvil 340. When the distal protrusion 316 engages the proximal cammingsurface 356 to lift the firing member 310 over the lock shoulder 336,the biasing force on the firing member 310 is overcome and the firingmember lockout is defeated. The proximal camming surface 356 does morethan just support the firing member 310, it cams the firing member 310upwardly away from the lock shoulder 336. Once the firing member 310 issupported on the sled 354, the firing member 310 can be advanceddistally to perform the staple firing stroke. Also notably, the firingmember 310 further comprises a cutting edge or knife 318 configured toincise patient tissue that has been captured between the anvil 340 andthe staple cartridge 350 during the staple firing stroke.

The entire disclosures of U.S. Pat. No. 7,143,923, entitled SURGICALSTAPLING INSTRUMENT HAVING A FIRING LOCKOUT FOR AN UNCLOSED ANVIL, whichissued on Dec. 5, 2006; U.S. Pat. No. 7,044,352, SURGICAL STAPLINGINSTRUMENT HAVING A SINGLE LOCKOUT MECHANISM FOR PREVENTION OF FIRING,which issued on May 16, 2006; U.S. Pat. No. 7,000,818, SURGICAL STAPLINGINSTRUMENT HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS, whichissued on Feb. 21, 2006; U.S. Pat. No. 6,988,649, SURGICAL STAPLINGINSTRUMENT HAVING A SPENT CARTRIDGE LOCKOUT, which issued on Jan. 24,2006; and U.S. Pat. No. 6,978,921, SURGICAL STAPLING INSTRUMENTINCORPORATING AN E-BEAM FIRING MECHANISM, which issued on Dec. 27, 2005,are incorporated by reference herein.

Other embodiments are envisioned where a longitudinal cavity is definedbetween the cartridge pan 352 and the elongate channel 330 when thestaple cartridge 350 and cartridge pan 352 are positioned in theelongate channel 330, for example. The first camming member 312 isconfigured to slide within the longitudinal cavity defined between thecartridge pan 352 and the elongate channel 330 during the staple firingstroke.

FIGS. 14-17 illustrate an end effector 420 of a surgical instrument 400.The surgical instrument 400 may be similar to the surgical instrument100, the surgical instrument 300, and/or or the surgical instrumentsdescribed herein. The end effector 420 comprises a first jaw or elongatechannel 430 and a second jaw or anvil. In at least one embodiment, theelongate channel 430 is movable relative to the anvil between an openposition and a closed position. In the illustrated embodiment, the anvilis pivotally coupled to the elongate channel 430 and movable relative tothe elongate channel 430 between an open position and a closed position.In either event, the elongate channel 430 is configured to receive astaple cartridge 450. The staple cartridge 450 is replaceable withanother staple cartridge, but may not be replaceable in otherembodiments. The staple cartridge 450 comprises a plurality of staplesremovably stored therein. The staples are prevented from falling out ofthe staple cartridge 450 by a cartridge pan 452 that is removablyattached to the staple cartridge 450. The staple cartridge 450 comprisesa sled 454 configured to move from a proximal unfired position P₀ (FIG.16) to an intermediate unfired position P₁ (FIG. 17) and then to adistal fired position to eject the staples from the staple cartridge450.

The elongate channel 430 comprises a channel opening 434 defined in thebottom of the elongate channel 430. The surgical instrument 400 furthercomprises a firing member 410 configured to travel through the endeffector 420 during a staple firing stroke to eject the staples from thestaple cartridge 450 when the staple cartridge 450 is positioned in theelongate channel 430 and the sled 454 is in its proximal unfiredposition P₀ or its intermediate unfired position P₁. The firing member410 comprises a lower lateral flange or first camming member 412, anupper lateral flange or second camming member 414, a distally-protrudingnose portion 416, and laterally-extending lock members 419. Thelaterally-extending lock members 419 are positioned intermediate thefirst camming member 412 and the second camming member 414 and extend inopposite directions. During the staple firing stroke, the first cammingmember 412 is configured to slideably engage the bottom of the elongatechannel 430 and the second camming member 414 is configured to slideablyengage an anvil slot defined in the anvil to position the anvil at adesired spacing relative to the elongate channel 430 and staplecartridge 450. Further, the laterally-extending lock members 419 areconfigured to travel within a longitudinal cavity 455 defined betweenthe staple cartridge 450 and the cartridge pan 452 during the staplefiring stroke. The distally-protruding nose portion 416—in conjunctionwith a rotating member of the sled 454 serve to overcome a firing memberlockout as described in greater detail below.

When a staple cartridge 450 is not positioned in the elongate channel430, the firing member 410 is locked out (i.e., prevented fromperforming the firing stroke). More specifically, if the staplecartridge 450 is not positioned in the elongate channel 430 and thefiring member 410 is actuated (i.e., advanced distally), the firingmember 410 is biased downwardly by a biasing member and thelaterally-extending lock members 419 of the firing member 410 are biasedinto a channel opening 434 in the elongate channel 430. The firingmember 410 is biased toward the channel opening 434 by a biasing membersuch as a spring, for example, in the shaft. When thelaterally-extending lock members 419 are biased into the channel opening434 and the firing member 410 is advanced distally, thelaterally-extending lock members 419 engage a distal wall or lockshoulder 436 of the channel opening 434 which prevents further distaladvancement of the firing member 410. Further, if the staple cartridge450 is positioned in the elongate channel 430 and the sled 454 ispositioned distal to the intermediate unfired position P₁, the firingmember 410 will be prevented from distally advancing in a similarmanner. In order to defeat the firing member lockout describe above, thesled 454 must be positioned at the intermediate unfired position P₁, orproximal to the intermediate unfired position P₁ when the staple firingstroke is initiated as described in greater detail below.

Referring primarily to FIGS. 16 and 17, the sled 454 comprises aproximal camming surface 456 and a lockout key or rotary member 458. Therotary member 458 is rotatable relative to the sled 454 between anunactuated position (FIG. 16) and an actuated position (FIG. 17). Thestaple cartridge 450 comprises a protrusion 451 that rotates the rotarymember 458 to rotate the rotary member 458 from the unactuated positionto the actuated position when the sled 454 is moved from the proximalunfired position P₀ to the intermediate unfired position P₁. In use,when the sled 454 is in the proximal unfired position P₀ and the firingmember 410 is advanced distally, the distally-protruding nose portion416 will slideably engage the proximal camming surface 456 of the sled454 and the firing member 410 will advance the sled 454 distally fromthe proximal unfired position P₀ toward the intermediate unfiredposition P₁ contacting the proximal camming surface 456, however, thisis not enough to lift the laterally-extending lock members 419 over thelock shoulder 436. As the sled 454 is advanced distally by the firingmember 410, the rotary member 458 engages the protrusion 451 of thestaple cartridge 450 and rotates the rotary member 458 from theunactuated position (FIG. 16) toward the actuated position (FIG. 17). Asthe rotary member 458 rotates from the unactuated position toward theactuated position, the rotary member 458 engages the distally-protrudingnose portion 416 of the firing member 410 and lifts the firing member410 over the lock shoulder 436 of the elongate channel 430. In otherwords, the laterally-extending lock members 419 are lifted over the lockshoulder 436 and are prevented from entering the channel opening andengaging the lock shoulder 436 owing to the lifting action of the rotarymember 458. Thus, an initial distal advancement of the sled 454 from theproximal unfired position P₀ toward the intermediate unfired position P₁defeats the firing member lockout. Further, the initial distaladvancement of the sled 454 from the proximal unfired position P₀ towardthe intermediate unfired position P₁ aligns the laterally-extending lockmembers 419 with the longitudinal cavity 455 and aligns the secondcamming member 414 with the anvil slot during the staple firing stroketo eject the staples. In the illustrated embodiment, the firing member410 further comprises a cutting edge or knife 418 configured to incisepatient tissue that has been captured between the anvil and the staplecartridge 450 during the staple firing stroke.

FIG. 18 illustrates a bailout assembly 500 of a surgical instrument suchas surgical instruments 100, 200, and/or 300 and/or the surgicalinstruments described in U.S. patent application Ser. No. 12/249,117,entitled POWERED SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLYRETRACTABLE FIRING SYSTEM, which is hereby incorporated herein byreference in its entirety. The bailout assembly 500 may be used, forexample, in the event the energy level of the surgical instrument'spower source falls below sufficient operational levels and the motorcan't be used to retract the firing system. The surgical instrumentcomprises a drive system 530 for driving a firing member 538 through astaple firing stroke. The drive system 530 comprises a motor 510, a gearbox 520 operably coupled the motor 510, a drive shaft 522 extending fromthe gear box 520, a drive gear 524 fixed to the drive shaft 522, adriven gear 535 operably engaged with the drive gear 524, and a driverack 532 operably engaged with the driven gear 535. The drive gear 524is configured to rotate in response to rotary motions generated by themotor 510. In at least one embodiment, the drive system 530 may behoused within a handle and/or housing of the surgical instrument.

Further to the above, the drive rack 532 comprises a first rack of teeth534 operably engaged with the driven gear 535 and a second rack of teeth536 operably engaged with the bailout assembly 500. In use, when arotary motion of a first direction is transmitted from the motor 510 tothe drive gear 524, the drive gear 524 is rotated in a counter-clockwisedirection and the driven gear 535 rotates in a clockwise direction. Whenthe driven gear 535 is rotated in a clockwise direction the drive rack532 and firing member 538 are translated distally to perform the staplefiring stroke. When a rotary motion of a second direction opposite thefirst direction is transmitted from the motor 510 to the drive gear 524,the drive gear 524 is rotated in a clockwise direction and the drivengear 535 rotates in a counter-clockwise direction. When the driven gear535 is rotated in a counter-clockwise direction the drive rack 532 istranslated proximally to retract the firing member 538.

Further to the above, the bailout assembly 500 comprises a lever 502 anda pawl 504 extending from the lever 502. The lever 502 is mounted to thehandle or housing of the surgical instrument such that the lever 502 isrotatable relative to the handle or housing. In at least one embodiment,the lever 502 is generally concealed from the user by an access door orpanel covering an opening in the handle or housing. The access door isremovable by the user to allow the user access to the lever 502 throughthe opening in the handle or housing of the instrument. In at least oneembodiment, the access door is coupled to an electronic switch and acontrol circuit such that when the clinician removes the access door,electric power to the motor 510 is cut, as described in greater detailbelow.

When the user actuates the bailout assembly 500, the pawl 504 of thebailout assembly 500 is configured to engage the second rack of teeth536. The pawl 504 is biased toward the second rack of teeth 536 by abiasing member such as a spring, for example. When the lever 502 isrotated clockwise, for example, the pawl 504 engages the second rack ofteeth 536 and drives the drive rack 532 and firing member 538proximally. When the drive rack 532 is driven proximally by the bailoutassembly 500, the motor 510 is back-driven. More specifically, thedriven gear 535 rotates counter-clockwise, the drive gear 524 rotatesclockwise, and the motor 510 is back-driven when the drive rack 532 isdriven proximally by the bailout assembly 500 as illustrated in FIG. 18.

In at least one embodiment, the motor 510 is an electro-magneticbrushless DC motor. The surgical instrument further comprises a powersource such as a battery or battery pack for example, and a controlcircuit including a microprocessor. The power source is configured tosupply power to the motor 510 and the control circuit is configured tocontrol the supply of power from the power source to the motor 510. Inat least one embodiment, the control circuit may be similar to thecontrol circuit 1200 comprising an emergency access door bailout switch1218 as described in U.S. Pat. No. 8,695,866, entitled SURGICALINSTRUMENT HAVING A POWER CONTROL CIRCUIT, which is hereby incorporatedherein by reference in its entirety. The emergency access door bailoutswitch cuts the flow of power from the power source to the motor 510when the access door is detached from the surgical instrument such thatwhen the motor is not accidently operated when manually driving thebailout assembly 500.

In at least one embodiment, the motor 510 is an electro-magneticbrushless DC motor comprising a capacitive timing element configured tocontrol the motor 510. In any event, utilizing a brushless DC motor anda motor control circuit eliminates the need to mechanically decouple themotor 510 from the drive system 530 when the bailout assembly 500 isactuated to retract the firing member 538. In at least one embodiment,the bailout assembly 500 is in electrical communication with the controlcircuit of instrument such that, when the lever 502 is actuated,electrical power is prevented from flowing from the power source to themotor 510 to allow the motor 510 to be back-driven as described above.

Further to the above, the control circuit is configured to adjust thespeed of the motor 510 during the firing stroke. More specifically, thecontrol circuit utilizes pulse width modulation to control the speed ofthe motor 510 and thus the speed of the firing stroke at certainpredefined locations with respect to the overall firing stroke (i.e. atthe end of stoke and/or at the beginning during a lockout portion of thefiring stroke), for example. In at least one embodiment, the controlcircuit could be located in a battery pack which acts as the powersource for the motor 510 as described in U.S. patent application Ser.No. 12/031,573, entitled SURGICAL CUTTING AND FASTENING INSTRUMENTHAVING RF ELECTRODES, which is hereby incorporated herein by referencein its entirety.

FIGS. 19-21 illustrates a surgical instrument 600 comprising a housing610, an elongate shaft 620 extending from the housing 610, an endeffector 630 extending from the elongate shaft 620, and an articulationjoint 640. The end effector 630 is rotatably coupled to the elongateshaft 620 by the articulation joint 640 and the elongate shaft 620 andthe end effector 630 are rotatable together about a longitudinal shaftaxis SA. The end effector 630 is rotatable about an articulation axis AArelative to the elongate shaft 620 by an articulation assembly 650comprising a first rod or articulation member 652, a second rod orarticulation member 654, and a manually-rotatable articulation knob 656.The articulation knob 656 extends away from the housing 610 of thesurgical instrument 600 so that it can be manually rotated by aclinician. The articulation assembly 650 comprises a shaft 657 extendingfrom the articulation knob 656 into the housing 610 and a yoke 658 whichconnects the articulation knob 656 to the first and second articulationmembers 652, 654. The first articulation member 652 is attached to afirst side of the yoke 658 and a first side of the end effector 630. Thesecond articulation member 654 is attached to a second side of the yoke658 opposite the first side of the yoke 658 and a second side of the endeffector 630 opposite the first side of the end effector 630. The firstand second articulation members 652, 654 are attached to the yoke 658via pins 659; however, any suitable attachment mechanism for attachingthe articulation members 652, 654 to the yoke 658 may be utilized.

In use, the articulation knob 656 is rotatable between an unarticulatedposition (shown in FIG. 19) and a plurality of articulated positions toarticulate the end effector 630 about the articulation axis AA. Theunarticulated position aligns the articulation knob 656 with theelongate shaft 620. When the articulation knob 656 is rotated clockwise,the yoke 658 rotates clockwise, the first articulation member 652 ismoved distally, the second articulation member is moved proximally 654,and the end effector 630 is rotated in clockwise about the articulationaxis AA. When the articulation knob 656 is rotated counter-clockwise,the yoke 658 rotates counter-clockwise, the first articulation member652 is moved proximally, the second articulation member is moveddistally 654, and the end effector 630 is rotated in counter-clockwiseabout the articulation axis AA.

Further to the above, the surgical instrument 600 further comprises anarticulation lock assembly 660 configured to lock the end effector 630relative to the elongate shaft 620. The articulation lock assembly 660comprises proximal lock member 664, a shaft 663 extending distally fromthe proximal lock member 664, and a distal lock member 662 extendingfrom the shaft 663. The distal lock member 662 comprises a protrusion665 configured to selectively engage a plurality of detents or teeth 632defined in the proximal end of the end effector 630. The articulationlock assembly 660 is biased toward the end effector 630 by a biasingmember or spring 670 positioned in the elongate shaft 620. Thearticulation lock assembly 660 is movable between a distal lockedposition (FIG. 20) where the protrusion 665 of the distal lock member662 is engaged with one of the teeth 632 of the end effector 630 and aproximal unlocked position (FIG. 21) where the protrusion 665 of thedistal lock member 662 is not engaged with any of the teeth 632 of theend effector 630. The articulation lock assembly 660 is moved betweenthe distal locked position and the proximal locked position when thearticulation knob 656 is rotated in either direction as described ingreater detail below.

The proximal lock member 664 comprises a carriage or collar 667positioned around the shaft 657 of the articulation assembly 650. Thecollar 667 comprises a protrusion 669 extending toward the shaft 657 ofthe articulation assembly 650. The articulation assembly 650 furthercomprises a plurality of detents or teeth 655 radially positioned aroundthe shaft 657. In the illustrated embodiment, a disc extending from theshaft 657 has the teeth 655 defined thereon. When the articulation knob656 is rotated counter-clockwise, for example, one of the teeth 655cammingly engages the protrusion 669 of the articulation lock assembly660 to drive the articulation lock assembly 660 proximally from thedistal locked position (FIG. 20) to the proximal unlocked position (FIG.21). When the articulation knob 656 is rotated in this manner, thearticulation lock assembly 660 is automatically unlocked and the firstand second articulation members 652, 654 are simultaneously rotating theend effector 630 about the articulation axis AA a predetermined amount.The predetermined amount is dependent upon the size, shape, and/orspacing of the teeth 655 of the articulation assembly 650 and the sizeand/or shape of the protrusion 669 of the articulation lock assembly660, among other things.

As discussed above, the articulation lock assembly 660 is biaseddistally by the spring 670. When the articulation knob 656 is rotated,the biasing force of the spring 670 is overcome and the articulationlock assembly 660 is driven proximally to the proximal unlockedposition. When the articulation knob 656 is rotated further, theprotrusion 669 of the articulation lock assembly 660 is aligned in arecess defined between adjacent teeth 655 and the articulation lockassembly 660 is once again biased distally by the spring 670 such thatthe distal lock member 662 is once again engaged with the end effector630 to lock the end effector 630 in position. This arrangement allowsthe end effector 630 to be rotated about the articulation axis AA andlocked into place in a plurality of rotated positions about thearticulation axis AA.

In at least one embodiment, an elongate staple cartridge channel of theend effector 630 comprises a plastic coating to minimize damage andbinding as a result of cleaning with caustic solutions. The plasticcoating is applied to the elongate channel by way of an injection moldedpolymer that is not highly hydrophilic, but could be applied in anysuitable manner. The molding material can comprise polyethylene,polycarbonate, nylon 6/12 with a glass or mineral fill, ABS, and/orcombinations thereof, for example. In at least one embodiment, theelongate channel comprises discrete features or cutouts arrayed aroundthe perimeter of the elongate channel which are contacted by the closuretube of the surgical instrument when the closure tube is advanceddistally. The cutouts limit the contact of the elongate channel with theclosure tube to small interfaces which minimize the damage to both theelongate channel and closure tube during repeated use. In at least oneembodiment, portions of the end effector 630, elongate shaft 620, andelongate channel are lubricated to prevent wear. In various embodiments,dried sodium stearate is applied to the internal structures of thesecomponents in such a manner as if they were wet-dipped and then dried.In certain embodiments, the elongate shaft 620 and/or any of the otherelements of the surgical instrument 600 may be dipped in the lubricantand baked to fixate the lubricants to the parts.

FIG. 22 illustrates a control circuit 700 for use with a surgicalinstrument such as the surgical instruments 100, 300, 400, 600, and/orthe surgical instruments described herein. The control circuit 700 isconfigured to control the supply of power from a power source to a motorsuch as the motor 510, for example. The power source may be a battery, abattery pack, a rechargeable battery pack or any combination thereof,for example. The control circuit 700 comprises a printed circuit board704, electrical components 706, a switch or rocker switch 710, and anelectrical port 720 configured to receive an electrical harness 730. Theelectrical components 706 comprise any combination of printed circuitboard components such as a processor, microprocessor, resistors, LEDs,transistors, capacitors, inductors, diodes, and switches, for example. Aconformal coating 702 is applied to the control circuit 700 to seal thecontrol circuit 700 from the surrounding environment. In at least oneembodiment, the conformal coating 702 comprises TECHNOMELT®; however,the conformal coating may comprise any suitable sealant flowed onto thecontrol circuit 700 to protect the control circuit 700 from thesurrounding environment. In at least one embodiment, the conformalcoating 702 is configured to protect the integrity of the controlcircuit 700 during one or more sterilization autoclave cycles. Thesterilization autoclave cycles may include temperatures ranging from 140degrees Celsius to 170 degrees Celsius, for example.

Referring now to FIG. 23, a seal such as gasket seal 740 is positionedbetween the conformal coating 702 and the rocker switch 710 to protectthe control circuit 700 from the surrounding environment. Further, therocker switch 710 comprises a flexible elastomer diaphragm 712 coveringthe switch 710 to maintain functionality of the switch 710 while stillprotecting the control circuit 700 from the surrounding environment. Invarious embodiments, electrical contacts on the rocker switch 710 aresoldered to electrical contacts on the circuit board 704. Surface mounttechnology and/or through-hole technology may be employed for theelectrical components of the circuit board 704. In at least oneembodiment, an adhesive is applied between the elastomer diaphragm 712and the rocker switch 710 to further seal the rocker switch 710 from thesurrounding environment. In at least one embodiment, the circuit board704 comprises a snap fit and/or press fit connection between the rockerswitch 710 and the circuit board 704.

Referring again to FIG. 22, a gasket seal 750 is positioned between theconformal coating 702 and the electrical harness 730 that iselectrically connected to the electrical port 720. The gasket seal 750protects the control circuit 700 from the surrounding environment andallows an exterior electrical input (the electrical harness 730) to beconnected to the control circuit 700. The electrical harness 730 may beconnected to the power source and/or the motor of a surgical instrument,for example.

Referring now to FIGS. 24 and 25 which illustrate seals for use betweena gear box and motor of a surgical instrument such as the surgicalinstruments disclosed herein. In at least one embodiment, the gear boxmay be the gear box 520 and the motor may be the motor 510, for example(see FIG. 18). A double-lipped seal 760 is positioned around the driveshaft 522 extending from the gear box 520. The double-lipped seal 760protects the gear box 520 from the surrounding environment. Further, adual o-ring 770 is positioned between the gear box 520 and motor 510 toseal the connection between the gear box 520 and motor 510 from thesurrounding environment. Further still, double-lipped seals 780 arepositioned around the electrical contacts extending from the bottom ofthe motor 510. The double-lipped seals 780 protect the motor 510 fromthe surrounding environment.

FIG. 26 illustrates a sterile packaging assembly 800 for a surgicalinstrument 850. The surgical instrument 850 may be similar to thesurgical instruments 100, 300, 400, 600, and/or the surgical instrumentsdescribed herein. The sterile packaging assembly 800 comprises a tray810 and a cover 820 secured to the tray 810. The tray 810 comprises aplurality of cavities 812 defined therein that are configured to receivethe surgical instrument 850. In at least one embodiment, the tray 810 isa vacuum-molded tray, but can be formed in any suitable manner. Thecavities 812 substantially mimic the outer profile of the surgicalinstrument 850 to properly and securely seat the surgical instrument 850in the tray 810 such that little, if any, relative shifting between thesurgical instrument 850 and the tray 810 can occur. The tray 810comprises additional cavities 816 defined in the tray 810 that areconfigured to receive supplemental components typically packaged withthe surgical instrument 850. In the illustrated embodiment, theadditional cavities 816 are configured to receive a battery pack 852,for example. However, other embodiments are envisioned with more or lesscavities 816 than the illustrated embodiment depending on the number ofsupplemental components packaged with a specific surgical instrument.

Further to the above, the tray 810 further comprises a plurality of trapcavities 814 defined in the tray 810. The trap cavities 814 areconfigured to receive particulate traps 830 and particulate traps 840.The particulate traps 830, 840 are configured to collect particulateswithin the packaging assembly 800 and trap the particulates within theparticulate traps 830, 840. The trap cavities 814 substantially mimicthe profiles of the particulate traps 830, 840 to properly and securelyseat the particulate traps 830, 840 in the tray 810 such that little, ifany, relative shifting between the particulate traps 830, 840 and thetray 810 can occur. After the particulate traps 830, 840 are assembledinto their respective trap cavities 814 in the tray 810, and thesurgical instrument 850 is seated in the tray 810, the cover 820 issecured to the tray 810 forming a sterile barrier. In at least oneembodiment, an additional film wrapping or sealant may be applied to atleast a portion of the packaging assembly 800 to further seal thepackaging assembly 800 from the surrounding environment.

Referring now to FIGS. 27-30, each of the particulate traps 830, 840comprise at least one concave surface or funnel shaped surfaceterminating in an opening. Referring to FIGS. 27 and 28, the particulatetrap 840 comprises an outer profile that is substantially cubic withfour side walls 842, a top wall 844, and a bottom wall 846. That said,the particulate trap 840 can comprise any suitable shape. Theparticulate trap 840 is hollow, i.e., it comprises a chamber or innercavity 841. In the illustrated embodiment, each of the four side walls842 comprise inwardly tapered surfaces 843 terminating in an opening 845that is in communication with the inner cavity 841. The tapered surfaces843 funnel particulates toward the openings 845 to aid in the collectionof the particulates within the particulate trap 840. Moreover, the innergeometry of the particulate trap 840 is arranged to inhibit theparticulates from falling out of the particulate trap 840. Among otherthings, the tapered surfaces 843 are defined on angled walls whichcreate partially-closed and tapered pockets with the particulate trap840. Stated another way, the tapered surfaces 843 are angled away fromthe opening 845 within the cavity 841 such that, once the particulatesenter the cavity 841, they are not easily expelled from the particulatetrap 840. The particulate trap 840 further comprises an adhesivematerial 847 positioned inside the cavity 841. One or more pieces oftwo-sided adhesive material are attached to the inner walls of theparticulate trap 840. The adhesive materials 847 help prevent theparticulates from exiting the particulate trap 840 and/or from rattlingaround inside the particulate trap 840.

Referring now to FIGS. 29 and 30, the particulate trap 830 comprises anouter profile that is a rectangular prism with four side walls 832, atop wall 834, and a bottom wall 836. The particulate trap 830 is hollow,i.e., it comprises a chamber or inner cavity 831. In the illustratedembodiment, the top wall 834 comprises an inwardly tapered surface 833terminating in an opening 835. The tapered surface 833 funnelsparticulates positioned on the outer profile of the particulate trap 830toward the opening 835 to aid in the collection of the particulateswithin the particulate trap 830. Further, the tapered surface 833 isangled away from the opening 835 within the cavity 831 such that oncethe particulates enter the cavity 831 they are not easily expelled fromthe particulate trap 830. The particulate trap 830 further comprises anadhesive material 837 positioned inside the cavity 831. The adhesivematerials 837 help prevent the particulates from exiting the particulatetrap 830 and/or from rattling around inside the particulate trap 830.

Further to the above, the particulate traps 830, 840 are positionable inthe tray 810 in a plurality of different configurations. The openings835, 845 are faced toward areas that are most likely to produceparticulates, for example. For instance, the openings 835, 845 can befaced toward the cavities 812, 816. In such instances, the openings 835,845 of the particulate traps 830, 840 are in communication with thecavities 812, 816. Other embodiments are envisioned with differentlysized and shaped particulate traps as the particulate traps 830, 840 arenot intended to be all encompassing but rather exemplary embodiments ofparticulate traps. The particulate traps may be opaque or the same coloras the tray 810, for example. In at least one embodiment, theparticulate traps comprise soundproofing material configured to reducethe noise generated by loose particulates rattling inside theparticulate traps. Such sound proofing material can comprise foam, forexample.

FIGS. 31 and 32 illustrate a surgical staple cartridge 900 for use witha surgical instrument, the surgical instrument comprises a jawconfigured to receive the staple cartridge 900 and a jaw including ananvil. The staple cartridge 900 and the anvil jaw are configured tocapture tissue therebetween which is then stapled and cut by thesurgical instrument. The staple cartridge 900 comprises a cartridge body910, a longitudinal slot 920 defined in the cartridge body 910, and adeck surface 930 positioned on either side of the longitudinal slot 920.The longitudinal slot 920 is configured to receive a cutting member ofthe surgical instrument. The cartridge body 910 comprises a plurality ofstaple cavities 932 defined therein. Each staple cavity 932 defines astaple cavity opening in the deck surface 930. The staple cavities 932are positioned in a plurality of longitudinal rows extending along thelength of the cartridge body 910. The longitudinal rows of staplecavities 932 are staggered relative to one another. Stated another way,each side of the deck surface 930 comprises an inner row of staplecavities 932 adjacent the longitudinal slot 920, an outer row of staplecavities 932, and an intermediate row of staple cavities 932 between theouter row of staple cavities 932 and the inner row of staple cavities932, wherein the staple cavities 932 of the intermediate row are shiftedlongitudinally with respect to the staple cavities 932 of the inner rowand outer rows. However, other embodiments are envisioned where the rowsof staple cavities 932 are not staggered relative to one another. In anyevent, each staple cavity 932 comprises a staple positioned thereinwhich is ejected out of the staple cavity opening of the staple cavity932 by a staple driver movably positioned within the staple cavity 932during a staple firing stroke.

Further to the above, the staple cartridge 900 further comprises alattice extension or honeycomb extension 940 extending above the decksurface 930. The honeycomb extension 940 comprises a plurality ofthrough holes 942 defined in the honeycomb extension 940. Each throughhole 942 extends through the honeycomb extension 940 and terminates atthe deck surface 930. Each through hole 942 is aligned with and incommunication with one of the staple cavity openings of the staplecavities 932 defined in the deck surface 930. Further, each through hole942 in the honeycomb extension 940 is larger than the correspondingstaple cavity opening that it is aligned with. Each through hole 942comprises an outer perimeter which at least partially aligns with anouter perimeter of a corresponding staple cavity opening of a staplecavity 932 in the deck surface 930. In the illustrated embodiment, thedistal end 946 of each through hole 942 is aligned with the distal endof a corresponding staple cavity opening and the proximal end 947 ofeach through hole 942 is aligned with a proximal end 937 of acorresponding staple cavity opening. The through holes 942 defined inthe honeycomb extension 940 are configured to prevent the flow of tissuerelative to the cartridge body 910 when the staples are ejected from thestaple cavities 932 during the staple firing stroke.

Further to the above, the honeycomb extension 940 comprises cutouts 944and cutouts 948 that are not in registration with and/or alignment withany of the staple cavities 932 defined in the deck surface 930. Eachcutout 948 extends through the honeycomb extension 940 and terminates inan outer deck surface 950 of a lug 952. Each lug 952 extends laterallyfrom the cartridge body 910 and is positioned below the deck surface 930of the cartridge body 910, as illustrated in FIG. 32. The cutouts 948and outer deck surfaces 950 provide additional surface area for theclamping and spreading of the tissue during the staple firing stroke.The cutouts 944 extend through the honeycomb extension 940 and terminateon the deck surface 930 but are not aligned with any of the staplecavity openings of the staple cavities 932. A portion of the honeycombextension 940 extends longitudinally beyond the deck surface 930adjacent the cutouts 944 as illustrated in FIG. 31.

Referring again to FIG. 31, the through holes 942 defined in thehoneycomb extension 940 vary in size and shape between each longitudinalrow of through holes 942. More specifically, the through holes 942positioned closest to the longitudinal slot 920 are smaller than thethrough holes 942 in the intermediate row of through holes 942. In anyevent, the size and shape of the through holes 942 as well as the sizeand shape of the cutouts 944 and 948 may vary relative to one another.The size, shape, and pattern of the through holes 942, the cutouts 944,and the cutouts 948 can be varied depending on the desired amount oftissue compression desired in a specific area of the staple cartridge900. Other embodiments are envisioned with differently sized and shapedthrough holes that the through holes 942 as the through holes 942 arenot intended to be all encompassing but rather exemplary embodiments ofa pattern of through holes. In any event, the through holes 942 allowthe tissue to flow toward the staple cavities 932 instead of away fromthe staple cavities 932. In at least one embodiment, a portion of thestaple cavity openings of the staple cavities 932 and the through holes942 support the legs of the staples as the staples are ejected from thestaple cartridge 900.

Referring now to FIGS. 33-59, a staple cartridge, such as staplecartridge 1000, for example, comprises a cartridge body 1010, aplurality of staple cavities 1012 defined in the cartridge body 1010,and a staple 1020 positioned in each of the staple cavities 1012. Thecartridge body 1010 further comprise a cartridge deck surface 1030. Theplurality of staple cavities 1012 define a plurality of staple cavityopenings in the cartridge deck surface 1030. Each of the staple cavities1012 comprises a pair of lateral sidewalls 1013 that oppose one anotherand converge at the proximal and distal ends of each staple cavity 1012.More specifically, each staple cavity 1012 comprises a pair of proximaltapered sidewalls 1014 and a pair of distal tapered sidewalls 1015. Theproximal tapered sidewalls 1014 converge toward one another andterminate in a proximal end wall 1016. The distal tapered sidewalls 1015converge toward one another and terminate in a distal end wall 1017. Thelateral sidewalls 1013, the tapered sidewalls 1014, 1015, the proximalend wall 1016, and the distal end wall 1017 form a perimeter of eachstaple cavity opening at the cartridge deck surface 1030. The cartridgebody 1010 further comprises a plurality of projections extending fromthe cartridge deck surface 1030. The projections may be sized and shapeddifferently and/or arranged in different pluralities, arrays, orpatterns on the cartridge deck surface 1030 to control the flow oftissue relative to the cartridge deck surface 1030, as described ingreater detail below.

Referring to FIGS. 33-36, a plurality of projections or posts 1040extend from the cartridge deck surface 1030. In at least one embodiment,the posts 1040 are cylindrical in shape and comprise a chamfered end.Other embodiments are envisioned where each post 1040 comprises a domedend. In any event, a post 1040 is positioned at the proximal and distalends of each staple cavity 1012. Further, the proximal end wall 1016 ofeach staple cavity 1012 is flush or aligned with the outer diameter ofthe post 1040 positioned at its proximal end and the distal end wall1017 of each staple cavity 1012 is flush or aligned with the outerdiameter of the post 1040. In the illustrated embodiment, the posts 1040are not interconnected with one another above the cartridge deck surface1030. In other words, the posts 1040 are only interconnected by thecartridge deck surface 1030 which they discretely extend from. Otherembodiments are envisioned where the posts 1040 are positioned adjacentto the staple cavities 1012 but are spaced away from the perimeter ofthe staple cavity openings defined in the cartridge deck surface 1030.Further, other embodiments are envisioned with the posts 1040 positionedat only one of the proximal and distal ends of each staple cavity 1012.

Referring to FIGS. 37-40, a plurality of projections or quarter-sphereridges 1050 extend from the cartridge deck surface 1030. Eachquarter-sphere ridge 1050 comprises a flat surface or face 1052 and anarcuate sphere portion 1054. A ridge 1050 is positioned at the distalend of each staple cavity 1012. Further, the distal end wall 1017 ofeach staple cavity 1012 is flush or aligned with the flat face 1052 ofthe ridge 1050 positioned at its distal end. In the illustratedembodiment, the ridges 1050 are not interconnected with one anotherabove the cartridge deck surface 1030. In other words, the ridges 1050are only interconnected by the cartridge deck surface 1030 which theydiscretely extend from. Other embodiments are envisioned where theridges 1050 are positioned adjacent to the staple cavities 1012 but arespaced away from the perimeter of the staple cavity openings defined inthe cartridge deck surface 1030. In addition to or in lieu of the above,other embodiments are envisioned with ridges 1050 positioned at theproximal end of each staple cavity 1012 with the flat face 1052 of eachridge 1050 flush or aligned with the proximal end wall 1016 of eachcorresponding staple cavity 1012.

Referring to FIGS. 41-44, a plurality of projections or cuboids 1060extend from the cartridge deck surface 1030. In at least one embodiment,the cuboids 1060 are substantially cubic in shape. A pair of cuboids1060 are positioned at the proximal and distal ends of each staplecavity 1012 adjacent to the proximal and distal tapered sidewalls 1014,1015. A face 1062 of each of the cuboids 1060 positioned at the proximalend of each staple cavity 1012 is flush or aligned with the proximaltapered sidewall 1014. Further, a face of each of the cuboids 1060positioned at the distal end of each staple cavity 1012 is flush oraligned with the distal tapered sidewall 1015. The cuboids 1060 are notinterconnected with one another above the cartridge deck surface 1030.In other words, the cuboids 1060 are only interconnected by thecartridge deck surface 1030 which they discretely extend from. Otherembodiments are envisioned where the cuboids 1060 are positionedadjacent to the staple cavities 1012 but are spaced away from theperimeter of the staple cavity openings defined in the cartridge decksurface 1030. Further, other embodiments are envisioned with a pair ofcuboids 1060 positioned at only the proximal or distal end of eachstaple cavity 1012.

Referring to FIGS. 45-48, a pair of posts 1040 are positioned at thedistal end of each staple cavity 1012 adjacent to the distal taperedsidewalls 1015. The outer diameter of each of the posts 1040 positionedat the distal end is flush or aligned with a distal tapered sidewall1015 of the staple cavity 1012. In addition to or in lieu of the above,a pair of posts 1040 are positioned at the proximal end of each staplecavity 1012 adjacent to the proximal tapered sidewalls 1014. In suchinstances, the outer diameter of each of the posts 1040 is positioned atthe proximal end of each staple cavity 1012 and is flush or aligned witha proximal tapered sidewall 1014 of the staple cavity 1012. The posts1040 are not interconnected with one another above the cartridge decksurface 1030. In other words, the posts 1040 are only interconnected bythe cartridge deck surface 1030 which they discretely extend from. Otherembodiments are envisioned where the posts 1040 are positioned adjacentto the staple cavities 1012 but are spaced away from the perimeter ofthe staple cavity openings defined in the cartridge deck surface 1030.

FIGS. 49-52 illustrate a combination of the embodiments illustrated inFIG. 33 and FIG. 41. More specifically, the staple cartridge 1000includes the cuboids 1060 arranged as they are in FIG. 41 and the posts1040 are arranged as they are in FIG. 33, for example. Other embodimentsare envisioned with a pair of cuboids 1060 and a post 1040 positioned atonly the proximal end or distal end of each staple cavity 1012.

FIGS. 53-55 illustrate another combination of the embodimentsillustrated in FIG. 33 and FIG. 41. More specifically, the staplecartridge 1000 includes a pair of cuboids 1060 positioned at the distalend of each staple cavity 1012 and a post 1040 positioned at theproximal end of each staple cavity 1012. As discussed above, a face 1062of each of the pair of cuboids 1060 is flush or aligned with the distaltapered sidewall 1015 on each side of the staple cavity 1012. See FIGS.41-44. The outer diameter of each post 1040 is flush or aligned with theproximal end wall 1016 of each staple cavity 1012. See FIGS. 33-36.Other embodiments are envisioned where the cuboids 1060 and posts 1040are positioned adjacent to the staple cavities 1012 but are spaced awayfrom the outer perimeter of the staple cavity openings of the staplecavities 1012.

Referring primarily to FIGS. 56-59, a plurality of arcuate projections1070 extend from the cartridge deck surface 1030. A pair of arcuateprojections 1070 are positioned at the proximal and distal end of eachstaple cavity 1012 adjacent to the proximal and distal tapered sidewalls1014, 1015. A face 1072 of each of the arcuate projections 1070 ispositioned at the proximal end of a staple cavity 1012 that is flush oraligned with the proximal tapered sidewall 1014. Further, a face 1072 ofthe arcuate projections 1070 positioned at the distal end of a staplecavity 1012 is flush or aligned with the distal tapered sidewall 1015.The arcuate projections 1070 are not interconnected with one anotherabove the cartridge deck surface 1030. In other words, the arcuateprojections 1070 are only interconnected by the cartridge deck surface1030 which they discretely extend from. Other embodiments are envisionedwhere the arcuate projections 1070 are positioned adjacent to the staplecavities 1012 but are spaced away from the perimeter of the staplecavity openings defined in the cartridge deck surface 1030. Further,other embodiments are envisioned in which a pair of arcuate projections1070 are positioned at only the proximal end or the distal end of eachstaple cavity 1012.

Various surgical instruments comprise powered and/or mechanical systemsfor performing surgical functions such as shaft rotation, end effectorarticulation, end effector jaw closure, and firing of the end effectorto staple and cut tissue positioned between the end effector jaws, forexample. In at least one embodiment, the mechanical and powered systemsinteract with one another to mechanically and/or electrically lock outone system based on the operation of another system, or systems, of thesurgical instrument, as described in greater detail below.

FIG. 60 illustrates a schematic of a surgical instrument 1100 comprisinga mechanical closure system 1110, a powered firing system 1120, apowered articulation system 1130, a powered shaft rotation system 1140,a control unit 1150, and a power source 1160. The control unit 1150 isconfigured to control the supply of power from the power source 1160 tothe powered firing system 1120, the powered articulation system 1130,and the powered shaft rotation system 1140.

The mechanical closure system 1110 may be similar to the mechanicalclosure systems described in U.S. Pat. No. 7,845,537, entitled SURGICALINSTRUMENT HAVING RECORDING CAPABILITIES, which is hereby incorporatedherein by reference in its entirety. The mechanical closure system 1110is configured to move a jaw of an end effector 1102 between an openposition and a closed position when a closure trigger 1112 is movedbetween an unclamped position and a clamped position. See FIG. 61. In atleast one embodiment, the mechanical closure system 1110 comprises alatch or lock that locks the closure trigger 1112 in the clampedposition. Further, a closure trigger release is utilized to unlock theclosure trigger 1112 from the clamped position. In various embodiments,the end effector closure system can comprise a motor-powered closuresystem.

The powered firing system 1120 may be similar to the powered firingsystems described in U.S. Pat. No. 7,845,537, entitled SURGICALINSTRUMENT HAVING RECORDING CAPABILITIES, which is hereby incorporatedherein by reference in its entirety. The powered firing system 1120comprises a firing motor 1122 of the surgical instrument 1100 such that,when power is supplied from the power source 1160 to the firing motor1122, the powered firing system 1120 moves a firing member of thesurgical instrument 1100 through a firing stroke and a retraction strokewithin the end effector 1102 of the surgical instrument 1100 to stapleand cut patient tissue.

The powered articulation system 1130 may be similar to the poweredarticulation systems described in U.S. Pat. No. 8,517,239, entitledSURGICAL STAPLING INSTRUMENT COMPRISING A MAGNETIC ELEMENT DRIVER, andU.S. Pat. No. 9,629,629, entitled CONTROL SYSTEMS FOR SURGICALINSTRUMENTS which are hereby incorporated herein by reference in theirentirety. The powered articulation system 1130 is operably engaged withan articulation motor 1132 of the surgical instrument 1100 such thatwhen power is supplied from the power source 1160 to the articulationmotor 1132 the end effector 1102 is articulated about an articulationaxis AA (see FIG. 62) relative to an elongate shaft 1118 of the surgicalinstrument 1100.

The powered shaft rotation system 1140 comprises a shaft rotation motor1142 in communication with the control unit 1150. The control unit 1150is configured such that, when power is supplied from the power source1160 to the shaft rotation motor 1142, the elongate shaft 1118 and endeffector 1102 are rotated about a longitudinal shaft axis SA defined bythe elongate shaft 1118. In various alternative embodiments, theelongate shaft 1118 and the end effector 1102 can be manually rotatedabout the longitudinal shaft axis SA.

When the surgical instrument 1100 is inserted into a patient cavity, thejaws of the end effector 1102 are in the closed position so that theyfit through a trocar or cannula inserted into the patient. After beinginserted into the patient cavity, the jaws of the end effector 1102 aremoved from the closed position to the open position by the mechanicalclosure system 1110. The end effector 1102 can then be articulated aboutthe articulation axis AA by the powered articulation system 1130 toposition the jaws of the end effector 1102 relative to patient tissue.An articulation sensor 1134 of the surgical instrument 1100 is in signalcommunication with the powered articulation system 1130 and the controlunit 1150. In the illustrated embodiment, the articulation sensor 1134is positioned on an articulation rod 1136 of the articulation system1130 and detects movement of the articulation rod 1136, see FIG. 62. Thearticulation sensor 1134 is configured to detect when the end effector1102 is being articulated about the articulation axis AA. In variousembodiments, the control unit 1150 is also configured to detect when theend effector 1102 is being articulated as the control unit 1150 controlsthe articulation motor 1132 driving the articulation system 1130.

When the end effector 1102 is being articulated, the control unit 1150prevents power from being supplied to the firing motor 1122. Also, thecontrol unit 1150 actuates a lock solenoid 1170 (see FIG. 63) of thesurgical instrument 1100 when the articulation system 1130 is beingactuated. The lock solenoid 1170 is in signal communication with thecontrol unit 1150 and comprises a mechanical member or pin 1172 whichextends into a portion of the mechanical closure system 1110 to preventthe closure system 1110 form being actuated when the lock solenoid 1170is actuated. The pin 1172 is retracted to permit the mechanical closuresystem 1110 to be actuated when the articulation sensor 1134 no longerdetects that the end effector 1102 is being articulated.

In at least one alternative embodiment, when the control unit 1150supplies power from the power source 1160 to the articulation motor1132, the control unit 1150 prevents the supply of power to the firingmotor 1122 and the lock solenoid 1170 is actuated to engage a carriage1114 of the mechanical closure system 1110 and prevents the mechanicalclosure system 1110 from being actuated. In such an arrangement, anarticulation sensor may not be necessary.

After the end effector 1102 has been articulated to the desiredorientation, the closure trigger 1112 of the mechanical closure system1110 can be actuated between the unclamped position and the clampedposition to capture tissue between the jaws of the end effector 1102.The mechanical closure system 1110 comprises a closure sensor 1113 insignal communication with the control unit 1150. The closure sensor 1113is configured to detect the position of the closure trigger 1112. Whenthe closure sensor 1113 detects that the closure trigger 1113 has beenmoved from the unclamped position toward the clamped position, thecontrol unit 1150 prevents the supply of power to the firing motor 1122,the articulation motor 1132, and the shaft rotation motor 1142. Thecontrol unit 1150 prevents the supply of power to the firing motor 1122unless the closure sensor 1113 detects that the closure trigger 1113 isin the clamped position (i.e., the jaws of the end effector 1102 are inthe closed position). In other words, the control unit 1150 prevents thepowered firing system 1120 from firing the end effector 1102 when thejaws of the end effector 1102 are in the open position or when the jawsare partially closed. When the jaws of the end effector 1102 are in theclosed position (i.e., the closure trigger 1112 is in the clampedposition), the control unit 1150 permits the supply of power to thefiring motor 1122 to allow the powered firing system 1120 to perform thefiring and retraction strokes within the end effector 1102.

Further to the above, the control unit 1150 prevents power from beingsupplied from the power source 1160 to the articulation motor 1132 andthe shaft rotation motor 1142 when power is supplied to the firing motor1122. The control unit 1150 controls the amount and direction of currentsupplied to the firing motor 1122 to advance the firing member from anunfired position to a fired position during a firing stroke and retractthe firing member from the fired position to the unfired position duringa retraction stroke after the firing stroke is complete. The firingmember is advanced through the end effector 1102 during the firingstroke when the firing motor 1122 is rotated in a first direction when afirst voltage polarity is applied to the firing motor 1122 and isretracted through the end effector during the retraction stroke when thefiring motor 1122 is rotated in a second direction opposite the firstdirection when a second voltage polarity opposite the first voltagepolarity is applied to the firing motor 1122.

The surgical instrument 1100 further comprises an encoder, for example,that can track the position of the firing member. The encoder is incommunication with the control unit 1150 which can determine whether ornot the firing member is in its proximal unfired position. The controlunit 1150 prevents the supply of power to the articulation motor 1132and the shaft rotation motor 1142 when the firing member is not in itsproximal unfired position. Further, the control unit 1150 operates theclosure trigger solenoid 1170 to lock the closure system 1110 in itsclosed configuration when the firing member is distal to its proximalunfired position.

In at least one embodiment, another solenoid in signal communicationwith the control unit 1150 and selectively engageable with the closuretrigger release prevents the closure trigger release from being actuatedto unlock the closure trigger 1112 from its clamped position. Morespecifically, a solenoid in signal communication with the control unit1150 may be actuated to mechanically engage the closure trigger releaseto prevent the closure trigger release from being actuated when thefiring member is not in the unfired position.

In at least one alternative embodiment, the elongate shaft 1118 and endeffector 1102 are rotatable about the longitudinal shaft axis SA by amanual rotation system 1140′. To prevent shaft rotation when the jaws ofthe end effector 1102 are in the process of being closed or when thejaws are closed, referring now to FIG. 64, the carriage 1114 of themechanical closure system 1110 operably engages the manual rotationsystem 1140′ of the surgical instrument. More specifically, a rotationnozzle 1144 is configured to be manually rotated to rotate the elongateshaft 1118 and the end effector 1102 about the longitudinal shaft axisSA. The rotation nozzle 1144 is journaled on the elongate shaft 1118such that the elongate shaft 1118 is translatable relative to therotation nozzle 1144. The carriage 1114 comprises a pin 1119 extendingtherefrom that is configured to engage the rotation nozzle 1144. Thecarriage 1114 is moved from a proximal position to a distal position toadvance the elongate shaft 1118 and move the jaws of end effector 1102between the open position and the closed position. When the carriage1114 is moved from the proximal position toward the distal position, thepin 1119 engages one of a plurality of holes defined in a rotaryindexing member 1146 of the rotation nozzle 1144 preventing the elongateshaft 1118 and end effector 1102 from being rotated about thelongitudinal shaft axis SA. When the carriage 1114 is retracted from itsdistal position toward its proximal position, the pin 1119 is disengagedfrom the nozzle 1144 such that the elongate shaft 1118 and end effector1102 can be rotated when the rotation nozzle 1144 is rotated.

As discussed above, the shaft rotation system is a manual shaft rotationsystem 1140′. See FIG. 64. In such an arrangement, the elongate shaft1118 and the end effector 1102 are not rotatable about the shaft axis SAunless the jaws of the end effector 1102 are in the open position owingto the lockout that is engaged when the closure system is closed.Further, the powered firing system 1120 cannot perform the firing strokeunless the jaws of the end effector 1102 are in the closed position(i.e., the closure trigger 1112 is in the clamped position) as discussedabove. Therefore, when the firing motor 1122 is actuated to move thefiring member through the firing stroke and retraction stroke, themanual shaft rotation system 1140′ is locked out preventing the elongateshaft 1118 and end effector 1102 from being rotated about the shaft axisSA.

As described above, the surgical instrument 1100 can comprise a poweredshaft rotation system 1140. The powered shaft rotation system 1140comprises the shaft rotation motor 1142 in communication with thecontrol unit 1150. The control unit 1150 is configured such that, whenthe end effector 1102 and elongate shaft 1118 are being rotated aboutthe shaft axis SA the mechanical closure system 1110, the powered firingsystem 1120, and the powered articulation system 1130 are locked out.More specifically, the control unit 1150 actuates the lock solenoid 1170to prevent the mechanical closure system 1110 from being actuated whenthe end effector 1102 and elongate shaft 1118 are being rotated.Further, the control unit 1150 prevents power form being supplied to thefiring motor 1122 and the articulation motor 1132 when the end effector1102 and the elongate shaft 1118 are being rotated, for example. In atleast one alternative embodiment, the powered shaft rotation system 1140may be employed in conjunction with a powered closure system, thepowered firing system 1120, and the powered articulation system 1130,for example. In such instances, when the powered shaft rotation system1140 is being actuated (i.e., the end effector 1102 and elongate shaft1118 are being rotated about the shaft axis) the control unit 1150prevents power from being supplied to the powered closure system and thepowered firing system 1120.

Various aspects of the subject matter described herein are set out inthe following examples.

Example Set 1

Example 1—A surgical instrument comprising an end effector and a handle.The handle comprises a drive system configured to actuate the endeffector and a battery dock comprising first electrical contacts. Thesurgical instrument further comprises a battery unit releasablyattachable to the battery dock. The battery unit comprises rechargeablebattery cells, a non-sterile housing, and a sterile housing. The batterycells are positioned in the non-sterile housing. The sterile housing isconfigured to receive the non-sterile housing. The sterile housingcomprises second electrical contacts configured to electrically couplethe battery cells of the non-sterile housing to the first electricalcontacts of the battery dock when the battery unit is attached to thebattery dock. The sterile housing further comprises a retention memberconfigured to secure the battery unit to the battery dock.

Example 2—The surgical instrument of Example 1, wherein the batterycells are positioned in the non-sterile housing such that all of thebattery cells are electrically connected at the same time.

Example 3—The surgical instrument of Examples 1 or 2, wherein at leastone battery cell of the battery cells is selected from the groupconsisting of a CR123 cell and a CR2 cell.

Example 4—The surgical instrument of Examples 1, 2, or 3, wherein thenon-sterile housing comprises means for indicating a charging status ofthe battery unit to a user of the surgical instrument.

Example 5—The surgical instrument of Examples 1, 2, 3, or 4, wherein thenon-sterile housing comprises a display configured to indicate to a userof the surgical instrument the remaining electrical capacity of thebattery cells, and wherein the remaining electrical capacity isdisplayed as a number of remaining actuations of the drive system.

Example 6—The surgical instrument of Examples 1, 2, 3, 4, or 5, whereinthe non-sterile housing comprises a display configured to indicate to auser of the surgical instrument the remaining electrical capacity of thebattery cells, and wherein the remaining electrical capacity isdisplayed as the time until the battery cells are drained when thebattery cells are discharged at a predetermined voltage, current, orpower level.

Example 7—The surgical instrument of Examples 1, 2, 3, 4, 5, or 6,wherein the non-sterile housing comprises a control circuit which limitsthe current draw of the surgical instrument to a predefined threshold.

Example 8—A surgical instrument comprising an end effector and a handle.The handle comprises a drive system configured to actuate the endeffector and a battery dock comprising first electrical contacts. Thesurgical instrument further comprises a battery unit releasablyattachable to the battery dock. The battery unit comprises rechargeablebattery cells, a first housing, and a second housing. The battery cellsare positioned in the first housing. The second housing is configured toreceive the first housing. The second housing is configured toencapsulate the first housing to create a sterile barrier between thefirst housing and the second housing. The second housing comprisessecond electrical contacts and a retention member. The second electricalcontacts are configured to electrically couple the battery cells of thefirst housing to the first electrical contacts of the battery dock whenthe battery unit is attached to the battery dock. The retention memberis configured to secure the battery unit to the battery dock.

Example 9—The surgical instrument of Example 8, wherein the batterycells are positioned in the first housing such that all of the batterycells are electrically connected at the same time.

Example 10—The surgical instrument of Examples 8 or 9, wherein at leastone battery cell of the battery cells is selected from the groupconsisting of a CR123 cell and a CR2 cell.

Example 11—The surgical instrument of Examples 8, 9, or 10, wherein thefirst housing comprises means for indicating a charging status of thebattery unit to a user of the surgical instrument.

Example 12—The surgical instrument of Examples 8, 9, 10, or 11, whereinthe first housing comprises a display configured to indicate to a userof the surgical instrument the remaining electrical capacity of thebattery cells, and wherein the remaining electrical capacity isdisplayed as a number of remaining actuations of the drive system.

Example 13—The surgical instrument of Examples 8, 9, 10, 11, or 12,wherein the first housing comprises a display configured to indicate toa user of the surgical instrument the remaining electrical capacity ofthe battery cells, and wherein the remaining electrical capacity isdisplayed as an amount of time until the battery cells are drained ifthe battery cells are discharged at a predetermined voltage, current, orpower level.

Example 14—The surgical instrument of Examples 8, 9, 10, 11, 12, or 13,wherein the first housing comprises a control circuit which limits thecurrent draw of the surgical instrument to a predefined threshold.

Example 15—A surgical instrument comprising an instrument housing and apower unit releasably attachable to the instrument housing. Theinstrument housing comprises a battery dock including a first electricalcontact. The power unit comprises rechargeable battery cells, a firsthousing, and a second housing. The battery cells are positioned in thefirst housing. The first housing is enclosed within the second housingto create a sterile barrier around the first housing. The second housingcomprises a second electrical contact and retention means for securingthe power unit to the instrument housing. The second electrical contactis configured to electrically couple the battery cells of the firsthousing to the first electrical contact of the battery dock when thepower unit is attached to the instrument housing.

Example 16—The surgical instrument of Example 15, wherein at least onebattery cell of the battery cells is selected from the group consistingof a CR123 cell and a CR2 cell.

Example 17—The surgical instrument of Examples 15 or 16, wherein thefirst housing comprises means for indicating a charging status of thepower unit to a user of the surgical instrument.

Example 18—The surgical instrument of Examples 15, 16, or 17, whereinthe first housing comprises a display configured to indicate to a userof the surgical instrument the remaining electrical capacity of thebattery cells, and wherein the remaining electrical capacity isdisplayed as a number of remaining uses of the surgical instrument.

Example 19—The surgical instrument of Examples 15, 16, 17, or 18,wherein the first housing comprises a display configured to indicate toa user of the surgical instrument the remaining electrical capacity ofthe battery cells, and wherein the remaining electrical capacity isdisplayed as an amount of time until the battery cells are drained ifthe battery cells are discharged at a predetermined voltage, current, orpower level.

Example 20—The surgical instrument of Examples 15, 16, 17, 18, or 19,wherein the first housing comprises a control circuit which limits thecurrent draw of the surgical instrument to a predefined threshold.

Example Set 2

Example 1—A battery pack for use with a surgical instrument. The batterypack comprises an outer housing, electrical contacts configured toelectrically couple the battery pack to the surgical instrument when thebattery pack is attached to the surgical instrument, a first pair ofbatteries, a second pair of batteries, an electrical connectorconfigured to electrically connect the first pair of batteries and thesecond pair of batteries, and an interruption member that prevents theelectrical connector from electrically connecting the first pair ofbatteries and the second pair of batteries until the interruption memberis displaced. The electrical connector electrically connects the firstpair of batteries and the second pair of batteries when the interruptionmember is displaced. The first pair of batteries and the second pair ofbatteries are electrically connected to the surgical instrument when theinterruption member is displaced and the battery pack is attached to thesurgical instrument.

Example 2—The battery pack of Examples 1, wherein the battery pack ispackaged in packaging, and wherein the interruption member is displacedwhen the battery pack is at least partially removed from the packaging.

Example 3—The battery pack of Examples 1 or 2, wherein the interruptionmember comprises a grippable tab extending from the battery pack.

Example 4—The battery pack of Examples 1, 2, or 3, wherein the firstpair of batteries and the second pair of batteries comprise CR123abatteries.

Example 5—The battery pack of Examples 1, 2, 3, or 4, wherein at leastone of the batteries is rechargeable.

Example 6—The battery pack of Examples 1, 2, 3, 4, or 5, wherein thefirst pair of batteries and the second pair of batteries areelectrically interrupted when the battery pack is detached from thesurgical instrument.

Example 7—A battery pack for use with a surgical instrument. The batterypack comprises a battery housing, batteries positioned in the batteryhousing, and an interruption member. The battery housing includeselectrical contacts configured to electrically couple the battery packto the surgical instrument when the battery pack is attached to thesurgical instrument. The interruption member is movable from a firstposition where the interruption member electrically disconnects at leastone battery from another battery and a second position. The batteriesare electrically connected to the surgical instrument when theinterruption member is moved from the first position to the secondposition and the battery pack is attached to the surgical instrument.

Example 8—The battery pack of Example 7, wherein the battery pack ispackaged in packaging, and wherein the interruption member is moved fromthe first position to the second position when the battery pack is atleast partially removed from the packaging.

Example 9—The battery pack of Examples 7 or 8, wherein the interruptionmember comprises a grippable tab extending from the battery pack.

Example 10—The battery pack of Examples 7, 8, or 9, wherein thebatteries comprise CR123a batteries.

Example 11—The battery pack of Examples 7, 8, 9, or 10, wherein at leastone of the batteries is rechargeable.

Example 12—The battery pack of Examples 7, 8, 9, 10, or 11, wherein thebatteries are electrically interrupted when the battery pack is detachedfrom the surgical instrument.

Example 13—A battery pack for use with a surgical instrument. Thebattery pack comprises a battery housing, batteries position in thebattery housing, an electrical circuit, and a circuit interrupter. Thebattery housing includes electrical contacts configured to electricallycouple the battery pack to the surgical instrument when the battery packis attached to the surgical instrument. The circuit interrupter ismovable from a first position where the circuit interrupter electricallydisconnects at least one battery from the electrical circuit and asecond position where all of the batteries are electrically connected tothe electrical circuit. The batteries are electrically connected to thesurgical instrument when the circuit interrupter is moved from the firstposition to the second position and the battery pack is attached to thesurgical instrument.

Example 14—The battery pack of Example 13, wherein the battery pack ispackaged in packaging, and wherein the circuit interrupter is moved fromthe first position to the second position when the battery pack is atleast partially removed from the packaging.

Example 15—The battery pack of Examples 13 or 14, wherein the circuitinterrupter comprises a grippable tab extending from the battery pack.

Example 16—The battery pack of Examples 13, 14, or 15, wherein thebatteries comprise CR123a batteries.

Example 17—The battery pack of Examples 13, 14, 15, or 16, wherein atleast one of the batteries is rechargeable.

Example 18—The battery pack of Examples 13, 14, 15, 16, or 17, whereinthe batteries are electrically interrupted when the battery pack isdetached from the surgical instrument.

Example Set 3

Example 1—A surgical instrument comprising a staple cartridge, an anvil,a firing member, an elongate channel, and a firing lockout. The staplecartridge comprises a cartridge body, staples, a cartridge panreleasably attached to the staple cartridge, and a sled configured toeject the staples from the staple cartridge. The sled is movable from aproximal position to a distal position. One of the anvil and the staplecartridge is movable relative to the other of the anvil and the staplecartridge. The anvil comprises an anvil slot. The firing member isconfigured to move the sled from the proximal position to the distalposition to eject the staples from the staple cartridge during a firingstroke. The firing member comprises a cutting edge, a first cammingmember, a second camming member configured to engage the anvil slotduring the firing stroke, and a distal protrusion. The elongate channelis configured to receive the staple cartridge. A longitudinal cavity isdefined between the cartridge pan and the elongate channel when thestaple cartridge is received in the elongate channel. The longitudinalcavity is configured to receive the first camming member during thefiring stroke. The elongate channel comprises a channel opening. Thelockout is enabled when the staple cartridge is not positioned in theelongate channel or when the staple cartridge is positioned in theelongate channel and the sled is not in the proximal position. Thefiring member engages a distal end of the channel opening to prevent thefiring member from performing the firing stroke when the lockout isenabled. The lockout is defeated when the sled is in the proximalposition and the distal protrusion of the firing member engages the sledand prevents the firing member from engaging the channel opening.

Example 2—The surgical instrument of Example 1, wherein the sled isconfigured to align the first camming member with the longitudinalcavity and the second camming member with the anvil slot when thelockout is defeated.

Example 3—The surgical instrument of Examples 1 or 2, wherein the staplecartridge is replaceable.

Example 4—The surgical instrument of Examples 1, 2, or 3, wherein thefiring member is biased into the channel opening by a biasing memberwhen the lockout is enabled.

Example 5—The surgical instrument of Example 4, wherein the sledcomprises a proximal camming portion configured to cammingly engage thedistal protrusion of the firing member to overcome the force of thebiasing member and defeat the lockout.

Example 6—The surgical instrument of Examples 1, 2, 3, 4, or 5, whereinthe firing member is lifted out of the channel opening by the sled whenthe lockout is defeated.

Example 7—A surgical instrument comprising a staple cartridge, an anvil,a firing member, an elongate channel, and a biasing member. The staplecartridge comprises a cartridge body, staples, a cartridge panreleasably attached to the staple cartridge, and a sled configured toeject the staples from the staple cartridge. The sled is movable from aproximal position to a distal position. One of the anvil and the staplecartridge is movable relative to the other of the anvil and the staplecartridge. The anvil comprises an anvil slot. The firing member isconfigured to move the sled from the proximal position to the distalposition to eject the staples from the staple cartridge during a firingstroke. The firing member comprises a cutting edge, a first cammingmember, a second camming member configured to engage the anvil slotduring the firing stroke, and a distal protrusion. The elongate channelis configured to receive the staple cartridge. A longitudinal cavity isdefined between the cartridge pan and the elongate channel when thestaple cartridge is received in the elongate channel. The longitudinalcavity is configured to receive the first camming member during thefiring stroke. The elongate channel comprises a channel opening. Thebiasing member is configured to apply a biasing force to the firingmember and move the firing member into the channel opening when the sledis not in the proximal position. The firing member is prevented fromperforming the firing stroke when the firing member is positioned in thechannel opening. The biasing force of the biasing member is overcomewhen the sled is in the proximal position and engages the distalprotrusion of the firing member. The firing member is removed from thechannel opening when the sled engages the distal protrusion.

Example 8—The surgical instrument of Example 7, wherein the sled isconfigured to align the first camming member with the longitudinalcavity and the second camming member with the anvil slot when the sledis in the proximal position.

Example 9—The surgical instrument of Examples 7 or 8, wherein the staplecartridge is replaceable.

Example 10—The surgical instrument of Examples 7, 8, or 9, wherein thesled comprises a proximal camming portion configured to cammingly engagethe distal protrusion of the firing member to overcome the biasing forceof the biasing member.

Example 11—The surgical instrument of Examples 7, 8, 9, or 10, whereinthe firing member is lifted out of the channel opening by the sled whenthe sled is in the proximal position.

Example 12—A surgical instrument comprising a staple cartridge, ananvil, a firing member, an elongate channel, and a lockout. The staplecartridge comprises a cartridge body, staples, a cartridge panreleasably attached to the staple cartridge, and a sled configured toeject the staples from the staple cartridge. The sled is movable from aproximal position to a distal position. The sled comprises a proximalcamming portion. One of the anvil and the staple cartridge is movablerelative to the other of the anvil and the staple cartridge. The anvilcomprises an anvil slot. The firing member is configured to move thesled from the proximal position to the distal position to eject thestaples from the staple cartridge during a firing stroke. The firingmember comprises, a cutting edge, a first camming member, a secondcamming member configured to engage the anvil slot during the firingstroke, and a distal protrusion. The elongate channel is configured toreceive the staple cartridge. A longitudinal cavity is defined betweenthe cartridge pan and the elongate channel when the staple cartridge isreceived in the elongate channel. The longitudinal cavity is configuredto receive the first camming member during the firing stroke. Theelongate channel comprises a channel opening. The lockout is configuredto prevent the firing member from performing the firing stroke when thesled is not in the proximal position. The firing member is configured toengage the channel opening when the sled is not in the proximalposition. The lockout is further configured to permit the firing memberto perform the firing stroke when the staple cartridge is positioned inthe elongate channel, the sled is in the proximal position, and theproximal camming portion of the sled engages the distal protrusion ofthe firing member and moves the firing member out of engagement with thechannel opening.

Example 13—The surgical instrument of Example 12, wherein the sled isconfigured to align the first camming member with the longitudinalcavity and the second camming member with the anvil slot when theproximal camming portion engages the distal protrusion of the firingmember.

Example 14—The surgical instrument of Examples 12 or 13, wherein thestaple cartridge is replaceable.

Example 15—The surgical instrument of Examples 12, 13, or 14, whereinthe firing member is biased into the channel opening by a biasing memberwhen the sled is not in the proximal position.

Example 16—The surgical instrument of Example 15, wherein the proximalcamming portion of the sled is configured to cammingly engage the distalprotrusion of the firing member to overcome the force of the biasingmember to permit the firing member to perform the firing stroke.

Example 17—The surgical instrument of Examples 12, 13, 14, 15, or 16,wherein the firing member is lifted toward the anvil when the proximalcamming portion engages the distal protrusion of the firing member.

Example Set 4

Example 1—A surgical instrument comprising an elongate channel, ananvil, a staple cartridge, a firing member, and a lockout key. Theelongate channel comprises a lock shoulder. The staple cartridgecomprises staples and a sled movable from a proximal end position to anintermediate position and then to a distal position during a staplefiring stroke. The firing member is movable distally to advance the sledthrough the staple cartridge during the staple firing stroke to ejectthe staples from the staple cartridge. The firing member comprises acutting edge, a first camming member configured to engage the elongatechannel during the staple firing stroke, and a second camming memberconfigured to engage the anvil during the staple firing stroke, and alockout key movably mounted to the sled. The lockout key is movablebetween an unactuated position and an actuated position during thestaple firing stroke. The key lifts the firing member over the lockshoulder when the lockout key is moved from the unactuated positiontoward the actuated position.

Example 2—The surgical instrument of Example 1, wherein the lockout keycomprises a rotary member configured to rotate relative to the sled, andwherein the rotary member is movable between a starting position and arotated position when the sled is moved from the proximal end positionto the intermediate position.

Example 3—The surgical instrument of Example 2, wherein the rotarymember lifts the firing member over the lock shoulder when the sled ismoved from the proximal end position to the intermediate position.

Example 4—The surgical instrument of Examples 2 or 3, wherein the staplecartridge further comprises a protrusion configured to engage the rotarymember to move the rotary member from the starting position to therotated position when the sled is moved from the proximal end positionto the intermediate position.

Example 5—The surgical instrument of Examples 1, 2, 3, or 4, wherein thefiring member comprises a laterally extending member intermediate thefirst camming member and the second camming member, and wherein thelockout key lifts the laterally extending member over the lock shoulderwhen the lockout key is moved from the unactuated position toward theactuated position.

Example 6—The surgical instrument of Examples 1, 2, 3, 4, or 5, whereinthe staple cartridge is replaceable.

Example 7—A surgical instrument comprising an elongate channel, ananvil, a staple cartridge, a firing member, and a lockout key. Theelongate channel comprises a blocking member. The staple cartridgecomprises staples and a sled movable from a proximal end position to anintermediate position and then to a distal position during a staplefiring stroke. The firing member is movable distally to advance the sledthrough the staple cartridge during the staple firing stroke to ejectthe staples from the staple cartridge. The firing member comprises acutting edge. The lockout key is movably mounted to the sled. Thelockout key is movable between an unactuated position and an actuatedposition during the staple firing stroke. The lockout key lifts thefiring member over the blocking member when the lockout key is movedfrom the unactuated position toward the actuated position.

Example 8—The surgical instrument of Example 7, wherein the lockout keycomprises a rotary member configured to rotate relative to the sled, andwherein the rotary member is movable from a starting position and arotated position when the sled is moved from the proximal end positionto the intermediate position.

Example 9—The surgical instrument of Example 8, wherein the rotarymember lifts the firing member over the blocking member when the sled ismoved from the proximal end position toward the intermediate position.

Example 10—The surgical instrument of Examples 8 or 9, wherein thestaple cartridge further comprises a protrusion configured to engage therotary member and move the rotary member from the starting position tothe rotated position when the sled is moved from the proximal endposition to the intermediate position.

Example 11—The surgical instrument of Examples 7, 8, 9, or 10, whereinthe staple cartridge is replaceable.

Example 12—A surgical instrument comprising an anvil, a staplecartridge, an elongate channel, and a firing member. The staplecartridge comprises staples and a sled movable from a proximal endposition to an intermediate position and then to a distal end positionduring a staple firing stroke. The elongate channel is configured toreceive the staple cartridge. The elongate channel comprises a lockshoulder. The firing member is movable distally to advance the sledthrough the staple cartridge during the staple firing stroke to ejectthe staples from the staple cartridge. The sled is configured totransition the firing member from a locked configuration where thefiring member is prevented from distally advancing by the lock shoulderand an unlocked configuration where the firing member is permitted todistally advance. The firing member is transitioned from the lockedconfiguration to the unlocked configuration when the sled is moved fromthe proximal end position to the intermediate position.

Example 13—The surgical instrument of Example 12, wherein the firingmember is in the locked configuration when the staple cartridge is notpresent in the elongate channel.

Example 14—The surgical instrument of Examples 12 or 13, wherein thelock shoulder comprises a distal end of an opening in the elongatechannel.

Example 15—The surgical instrument of Examples 12, 13, or 14, whereinthe firing member further comprises a cutting edge, a first cammingmember configured to engage the anvil during the staple firing stroke,and a second camming member configured to engage the elongate channelduring the staple firing stroke.

Example 16—The surgical instrument of Example 12, wherein the firingmember is biased into the locked configuration by a biasing member, andwherein the biasing member imparts a biasing force on the firing member.

Example 17—The surgical instrument of Example 16, wherein the sled isconfigured to lift the firing member over the lock shoulder and overcomethe biasing force of the biasing member when the sled moves from theproximal end position to the intermediate position.

Example 18—The surgical instrument of Examples 12, 13, 14, 15, 16, or17, wherein the sled comprises a lockout key movable from an unactuatedposition to an actuated position when the sled is moved from theproximal end position to the intermediate position, and wherein thelockout key lifts the firing member over the lock shoulder when thelockout key is moved toward the actuated position.

Example 19—The surgical instrument of Example 18, wherein the lockoutkey is configured to engage a protrusion in the staple cartridge to movethe lockout key from the unactuated position to the actuated position.

Example 20—The surgical instrument of Examples 12, 13, 14, 15, 16, 17,18, or 19, wherein the staple cartridge is replaceable.

Example Set 5

Example 1—A surgical instrument for fastening and stapling tissue. Thesurgical instrument comprises an end effector, a firing member, and ahousing. The firing member is configured to move relative to the endeffector during a firing stroke. The housing comprises a drive rackoperably engaged with the firing member, a drive gear operably engagedwith the drive rack, and a brushless motor operably engaged with thedrive gear. The brushless motor is configured to transmit rotary motionsto the drive gear. The housing further comprises a power sourceconfigured to supply power to the brushless motor, an access opening, anaccess door covering the access opening, a control circuit configured tocontrol the supply of power from the power source to the brushlessmotor, and a bailout lever accessible by a user of the surgicalinstrument through the access opening. The bailout lever is configuredto be manually actuated by the user of the surgical instrument betweenan unactuated position and an actuated position to retract the driverack and the firing member. The brushless motor is back-driven when thebailout lever is moved from the unactuated position toward the actuatedposition.

Example 2—The surgical instrument of Example 1, wherein the controlcircuit comprises a bailout switch, wherein the bailout switch is in aclosed state when the access door is closed, and wherein the bailoutswitch is in an open state when the access door is open.

Example 3—The surgical instrument of Example 2, wherein the controlcircuit is configured to permit power to flow from the power source tothe brushless motor when the bailout switch is in the closed state, andwherein the control circuit is configured to prevent power from flowingto the brushless motor from the power source when the bailout switch isin the open state.

Example 4—The surgical instrument of Examples 1, 2, or 3, wherein thecontrol circuit comprises a pulse width modulation control circuitconfigured to control the speed of the brushless motor during the firingstroke.

Example 5—The surgical instrument of Examples 1, 2, 3, or 4, wherein thepower source comprises a replaceable battery pack.

Example 6—The surgical instrument of Examples 1, 2, 3, 4, or 5, whereinthe brushless motor comprises a brushless DC motor.

Example 7—The surgical instrument of Examples 1, 2, 3, 4, 5, or 6,wherein the firing member is configured to perform multiple the firingstrokes.

Example 8—A surgical instrument for fastening and cutting tissue. Thesurgical instrument comprises a firing member, a drive assembly, acontrol circuit, and a bailout lever. The firing member is movabledistally during a firing stroke. The drive assembly comprises a driverack operably engaged with the firing member, a drive gear operablyengaged with the drive rack, and a brushless motor operably engaged withthe drive gear. The brushless motor is configured to transmit rotarymotions to the drive gear. The control circuit is configured to controlthe supply of power from a power source to the brushless motor. Thebailout lever is configured to be manually actuated by a user of thesurgical instrument between an unactuated position and an actuatedposition to retract the firing member. The brushless motor isback-driven when the bailout lever is moved from the unactuated positionto the actuated position.

Example 9—The surgical instrument of Example 8, further comprising ahousing configured to receive the drive assembly. The housing comprisesan access opening and an access door covering the access opening.

Example 10—The surgical instrument of Example 9, wherein the bailoutlever is accessible by the user of the surgical instrument through theaccess opening when the access door is removed.

Example 11—The surgical instrument of Example 10, wherein the controlcircuit comprises a bailout switch, wherein the bailout switch is in aclosed state when the access door is covering the access opening, andwherein the bailout switch is in an open state when the access door isremoved.

Example 12—The surgical instrument of Example 11, wherein the controlcircuit is configured to permit power to flow from the power source tothe brushless motor when the bailout switch is in the closed state, andwherein the control circuit is further configured to prevent power fromflowing to the brushless motor from the power source when the bailoutswitch is in the open state.

Example 13—The surgical instrument of Examples 8, 9, 10, 11, or 12,wherein the control circuit comprises a pulse width modulation controlcircuit configured to control the speed of the brushless motor atvarious times during the firing stroke.

Example 14—The surgical instrument of Examples 8, 9, 10, 11, 12, or 13,wherein the power source comprises a replaceable battery pack.

Example 15—The surgical instrument of Examples 8, 9, 10, 11, 12, 13, or14, wherein the power source comprises a battery.

Example 16—The surgical instrument of Examples 8, 9, 10, 11, 12, 13, 14,or 15, further comprising an end effector comprising a staple cartridgeincluding a plurality of staples configured to be ejected from thestaple cartridge during the firing stroke.

Example 17—A surgical instrument for fastening and cutting tissue. Thesurgical instrument comprises a firing member, a housing, a bailoutlever, and a control circuit. The firing member is movable through afiring stroke. The housing comprises a drive rack operably engaged withthe firing member, a drive gear operable engaged with the drive rack,and a brushless motor operably engaged with the drive gear. Thebrushless motor is configured to transmit rotary motions to the drivegear. The housing further comprises an access opening and a coverreleasably attached to the housing to cover the access opening. Thebailout lever is accessible by a user of the surgical instrument throughthe access opening when the cover is detached from the housing. Thebailout lever is configured to be manually actuated by the user of thesurgical instrument between an unactuated position and an actuatedposition to retract the firing member. The brushless motor isback-driven when the bailout lever is moved from the unactuated positionto the actuated position. A control circuit configured to control thesupply of power from a power source to the brushless motor. The controlcircuit is configured to prevent the power source from supplying powerto the brushless motor when the cover is detached from the housing.

Example 18—The surgical instrument of Example 17, wherein the controlcircuit comprises a pulse width modulation control circuit configured tocontrol the speed of the brushless motor at various times during thefiring stroke.

Example 19—The surgical instrument of Examples 17 or 18, wherein thepower source comprises a replaceable battery pack.

Example 20—The surgical instrument of Examples 17, 18, or 19, whereinthe power source comprises a battery.

Example Set 6

Example 1—A surgical instrument comprising a handle, an elongate shaft,an end effector, an articulation joint, an articulation knob, a firstarticulation member, a second articulation member, and an articulationlock. The elongate shaft extends from the handle and defines a shaftaxis. The end effector comprising a plurality of detents. The endeffector is rotatably coupled to the elongate shaft by the articulationjoint about an articulation axis. The articulation knob is rotatablebetween an unarticulated position and articulation positions. The firstarticulation member is attached to a first side of the end effector andto the articulation knob. The second articulation member is attached toa second side of the end effector and to the articulation knob. Thearticulation lock comprises a lock member configured to move between alocked position where the lock member is engaged with a detent of theend effector and an unlocked position where the lock member isdisengaged from the end effector. The lock member is movable between thelocked position and the unlocked position by the articulation knob. Thefirst articulation member and the second articulation member are movedin opposite directions to articulate the end effector about thearticulation axis when the articulation knob is moved from theunarticulated position toward an articulated position.

Example 2—The surgical instrument of Example 1, wherein the lock memberis moved proximally when the lock member moves from the locked positionto the unlocked position.

Example 3—The surgical instrument of Examples 1 or 2, wherein the lockmember is biased into the locked position by a biasing member.

Example 4—The surgical instrument of Examples 1, 2, or 3, wherein thelock member comprises a carriage including a protrusion configured toengage the articulation knob, and wherein the carriage surrounds aportion of the articulation knob.

Example 5—The surgical instrument of Example 4, wherein the articulationknob comprises a plurality of knob detents, and wherein a knob detentengages the protrusion and moves the carriage and the lock memberproximally when the articulation knob is moved from the unarticulatedposition toward an articulated position.

Example 6—The surgical instrument of Examples 1, 2, 3, 4, or 5, whereinthe end effector comprises a staple cartridge.

Example 7—A surgical instrument comprising a handle, an elongate shaft,an end effector, an articulation joint, an articulation knob, a firstarticulation member, a second articulation member, and an articulationlock. The elongate shaft extends from the handle and defines a shaftaxis. The end effector comprising a plurality of detents. The endeffector is rotatably coupled to the elongate shaft by the articulationjoint about an articulation axis. The articulation knob is rotatablebetween an unarticulated position and articulation positions. The firstarticulation member is attached to a first side of the end effector andto the articulation knob. The second articulation member is attached toa second side of the end effector and to the articulation knob. Rotationof the articulation knob moves the first articulation member and thesecond articulation member in opposite directions to articulate the endeffector about the articulation axis. The articulation lock comprises adistal lock member and a proximal lock member. The distal lock member isselectively engageable with the end effector. The end effector isprevented from rotating when the distal lock member is engaged with theend effector. The proximal lock member is operably engaged with thearticulation knob. The articulation lock is configured to betransitioned between a locked state where the distal lock member isengaged with the end effector and an unlocked state where the distallock member is disengaged with the end effector. Rotation of thearticulation knob between the unarticulated position and an articulatedposition transitions the articulation lock from the locked state to theunlocked state and then into the locked state again.

Example 8—The surgical instrument of Example 7, wherein the proximallock member is moved proximally when the articulation lock transitionsfrom the locked state to the unlocked state.

Example 9—The surgical instrument of Examples 7 or 8, wherein thearticulation lock is biased into the locked state by a biasing member.

Example 10—The surgical instrument of Examples 7, 8, or 9, wherein theproximal lock member comprises a carriage including a protrusionconfigured to engage the articulation knob, and wherein the carriagesurrounds a portion of the articulation knob.

Example 11—The surgical instrument of Example 10, wherein thearticulation knob comprises a plurality of knob detents, and wherein aknob detent engages the protrusion and moves the carriage and theproximal lock member proximally when the articulation knob is moved fromthe unarticulated position toward an articulated position.

Example 12—The surgical instrument of Examples 7, 8, 9, 10, or 11,wherein the end effector comprises a staple cartridge.

Example 13—A surgical instrument comprising a handle, an elongate shaft,an end effector, an articulation joint, an articulation knob, anarticulation member, and an articulation lock. The elongate shaftextends from the handle and defines a shaft axis. The end effectorcomprises a plurality of detents. The end effector is rotatably coupledto the elongate shaft by the articulation joint about an articulationaxis. The articulation knob is rotatable between an un-rotated positionand rotated positions. The articulation member is attached to the endeffector and to the articulation knob. The articulation member ismovable between a proximal position and a distal position. Thearticulation lock comprises a lock member configured to move between alocked position where the lock member is engaged with a detent of theend effector and an unlocked position where the lock member isdisengaged from the end effector. The lock member is movable between thelocked position and the unlocked position by the articulation knob. Thearticulation member is moved between the proximal position and thedistal position to articulate the end effector about the articulationaxis when the articulation knob is moved from the un-rotated positiontoward a rotated position.

Example 14—The surgical instrument of Example 13, wherein the lockmember comprises a carriage including a protrusion configured to engagethe articulation knob, and wherein the carriage surrounds a portion ofthe articulation knob.

Example 15—The surgical instrument of Example 14, wherein thearticulation knob comprises a plurality of knob detents, and wherein aknob detent engages the protrusion and moves the carriage and the lockmember proximally when the articulation knob is moved from theun-rotated position toward a rotated position.

Example 16—The surgical instrument of Examples 13, 14, or 15, whereinthe end effector comprises a staple cartridge.

Example 17—A surgical instrument comprising a handle, an elongate shaft,an end effector, an articulation joint, an articulation knob, anarticulation member, and an articulation lock. The elongate shaftextends from the handle and defines a shaft axis. The end effectorcomprises a plurality of detents. The end effector is rotatably coupledto the elongate shaft by the articulation joint about an articulationaxis. The articulation knob is rotatable between an un-rotated positionand rotated positions. The articulation member is attached to the endeffector and to the articulation knob. The articulation member ismovable between a proximal position and a distal position. Thearticulation lock comprises a distal lock member and a proximal lockmember. The distal lock member is selectively engageable with the endeffector. The end effector is prevented from rotating when the distallock member is engaged with the end effector. The proximal lock memberis operably engaged with the articulation knob. The articulation lock isconfigured to be transitioned between a locked state where the distallock member is engaged with the end effector and an unlocked state wherethe distal lock member is disengaged with the end effector. Rotation ofthe articulation knob between the un-rotated position and a rotatedposition transitions the articulation lock from the locked state to theunlocked state and then into the locked state again.

Example 18—The surgical instrument of Example 17, wherein the proximallock member comprises a carriage including a protrusion configured toengage the articulation knob, and wherein the carriage surrounds aportion of the articulation knob.

Example 19—The surgical instrument of Example 18, wherein thearticulation knob comprises a plurality of knob detents, and wherein aknob detent engages the protrusion and moves the carriage and theproximal lock member proximally when the articulation knob is moved fromthe un-rotated position toward a rotated position.

Example 20—The surgical instrument of Examples 17, 18, or 19, whereinthe end effector comprises a staple cartridge.

Example Set 7

Example 1—A powered surgical stapler for stapling and cutting tissuecomprising a handle, an elongate shaft extending from the handle, an endeffector extending from the elongate shaft, a firing member, and anarticulation joint. The a handle comprises a motor configured togenerate a rotary motion, a battery pack configured to supply power tothe motor, and a control circuit configured to control the supply ofpower from the battery pack to the motor. The control circuit comprisesconformal coating which seals the control circuit from the environment.The handle further comprises a firing trigger and a closure trigger. Thefiring trigger is movable between an unactuated position and an actuatedposition. The closure trigger is movable between an unclamped positionand a clamped position. The end effector comprises an elongate channeland an anvil. The elongate channel is configured to receive a staplecartridge. The staple cartridge comprises a plurality of staplesremovably stored in the staple cartridge. The anvil is movable relativeto the elongate channel between an open position and a closed position.The end effector is configured to capture patient tissue between theanvil and the staple cartridge when the anvil is moved toward the closedposition. The anvil is moved from the open position toward the closedposition when the closure trigger is moved from the unclamped positiontoward the clamped position. The firing member is movable from anunfired position to a fired position to eject the staples from thestaple cartridge and cut the patient tissue during a firing stroke. Thefiring member is configured to perform the firing stroke when the firingtrigger is moved from the unactuated position toward the actuatedposition. The firing member can only perform the firing stroke when theclosure trigger is in the clamped position. The end effector isconfigured to rotate relative to the elongate shaft about thearticulation joint.

Example 2—The powered surgical stapler of Example 1, wherein theconformal coating is configured to survive a sterilization autoclavecycle.

Example 3—The powered surgical stapler of Example 2, wherein thesterilization autoclave cycle includes a temperature range of 140degrees Celsius to 170 degrees Celsius.

Example 4—The powered surgical stapler of Examples 1, 2, or 3, whereinthe conformal coating comprises a sealant flowed onto the controlcircuit.

Example 5—The powered surgical stapler of Examples 1, 2, 3, or 4,wherein the control circuit comprises a switch and an elastomerdiaphragm covering the switch, wherein the elastomer diaphragm isconfigured to seal the switch from the environment.

Example 6—The powered surgical stapler of Example 5, wherein the switchcomprises a manually actuatable rocker switch.

Example 7—The powered surgical stapler of Examples 5 or 6, furthercomprising a gasket seal positioned between the switch and the conformalcoating, wherein the gasket seal is configured to seal the controlcircuit from the environment.

Example 8—The powered surgical stapler of Examples 1, 2, 3, 4, 5, 6, or7, wherein the control circuit comprises an electrical port, wherein thepowered surgical stapler further comprises an electrical harnesselectrically connected to the electrical port and a gasket sealpositioned between the electrical port and the electrical harness, andwherein the gasket seal is configured to seal the control circuit fromthe environment.

Example 9—A powered surgical stapler for stapling and cutting tissue.The powered surgical stapler comprises a handle. The handle comprises amotor, a control circuit, a firing trigger, and a closure trigger. Themotor is configured to generate a rotary motion. The control circuit isconfigured to control the supply of power from a power source to themotor. The control circuit comprises a printed circuit board, electricalcomponents mounted to the printed circuit board, and a coating over theprinted circuit board and the electrical components which seals thecontrol circuit from the environment. The firing trigger is movablebetween an unactuated position and an actuated position. The closuretrigger is movable between an unclamped position and a clamped position.

Example 10—The powered surgical stapler of Example 9, wherein thecoating is configured to survive a sterilization autoclave cycle.

Example 11—The powered surgical stapler of Example 10, wherein thesterilization autoclave cycle includes a temperature range of 140degrees Celsius to 170 degrees Celsius.

Example 12—The powered surgical stapler of Examples 9, 10, or 11,wherein the coating comprises a sealant flowable onto the controlcircuit.

Example 13—The powered surgical stapler of Examples 9, 10, 11, or 12,wherein the control circuit comprises a switch and an elastomerdiaphragm covering the switch, wherein the elastomer diaphragm isconfigured to seal the switch from the environment.

Example 14—The powered surgical stapler of Example 13, wherein theswitch comprises a manually actuatable rocker switch.

Example 15—The powered surgical stapler of Examples 13 or 14, furthercomprising a gasket seal positioned between the switch and the coating,wherein the gasket seal is configured to seal the control circuit fromthe environment.

Example 16—The powered surgical stapler of Examples 9, 10, 11, 12, 13,14, or 15, wherein the control circuit comprises an electrical port,wherein the powered surgical stapler further comprises an electricalharness electrically connected to the electrical port and a gasket sealpositioned between the electrical port and the electrical harness, andwherein the gasket seal is configured to seal the control circuit fromthe environment.

Example 17—A powered surgical stapler for stapling and cutting tissue.The powered surgical staple comprises a handle, an elongate shaftextending from the handle, an end effector extending from the elongateshaft, and a firing member. The handle comprises a motor, a power pack,a control circuit, a firing trigger, and a closure trigger. The motor isconfigured to generate a rotary motion. The power pack is configured tosupply power to the motor. The power pack is releasably attachable tothe handle. The control circuit is configured to control the supply ofpower from the power pack to the motor. The control circuit comprisesconformal coating which prevents the control circuit from being exposedto the surrounding environment. The firing trigger is movable between anunactuated position and an actuated position. The closure trigger ismovable between an unclamped position and a clamped position. The endeffector comprises a first jaw, a second jaw, and an elongate channel.The second jaw is movable relative to the first jaw between an openposition and a closed position to clamp patient tissue between the firstjaw and the second jaw. The second jaw is moved from the open positiontoward the closed position when the closure trigger is moved from theunclamped position toward the clamped position. The elongate channel isconfigured to receive a staple cartridge. The staple cartridge comprisesa plurality of staples removably stored in the staple cartridge. Thefiring member is movable from an unfired position to a fired position toeject the staples from the staple cartridge and cut the patient tissueduring a firing stroke. The firing member is configured to perform thefiring stroke when the firing trigger is moved from the unactuatedposition toward the actuated position. The firing member can onlyperform the firing stroke when the closure trigger is in the clampedposition.

Example 18—The powered surgical stapler of Example 17, wherein theconformal coating is configured to survive a sterilization autoclavecycle.

Example 19—The powered surgical stapler of Example 18, wherein thesterilization autoclave cycle includes a temperature range of 140degrees Celsius to 170 degrees Celsius.

Example 20—The powered surgical stapler of Examples 17, 18, or 19,wherein the conformal coating comprises a sealant flowed onto thecontrol circuit.

Example Set 8

Example 1—A sterile packaging assembly configured to receive a surgicalinstrument. The sterile packaging assembly comprises a vacuum-moldedtray and a particulate trap. The vacuum-molded tray comprises aninstrument cavity configured to receive the surgical instrument, and atrap cavity. The particulate trap is positioned in the trap cavity. Theparticulate trap comprises a housing including a funnel shaped sideterminating in an opening. The opening is in communication with achamber defined in the particulate trap.

Example 2—The sterile packaging assembly of Example 1, wherein theparticulate trap further comprises an adhesive positioned in thechamber.

Example 3—The sterile packaging assembly of Examples 1 or 2, wherein theparticulate trap is opaque.

Example 4—The sterile packaging assembly of Examples 1, 2, or 3, whereinthe particulate trap is the same color as the vacuum-molded tray.

Example 5—The sterile packaging assembly of Examples 1, 2, 3, or 4,wherein the particulate trap further comprises a soundproofing material.

Example 6—The sterile packaging assembly of Examples 1, 2, 3, 4, or 5,wherein the housing comprises another funnel shaped side terminating inanother opening in communication with the chamber.

Example 7—The sterile packaging assembly of Examples 1, 2, 3, 4, 5, or6, wherein the particulate trap is not visible when the surgicalinstrument is positioned in the sterile packaging assembly.

Example 8—The sterile packaging assembly of Examples 1, 2, 3, 4, 5, 6,or 7, wherein the vacuum-molded tray comprises another trap cavity,wherein the sterile packing assembly comprises another particulate trappositioned in the another trap cavity.

Example 9—A sterile packaging assembly configured to receive a surgicalinstrument. The sterile packaging assembly comprises a tray and a hollowparticulate trap. The tray comprises an instrument cavity configured toreceive the surgical instrument, and a trap cavity. The hollowparticulate trap is positioned in the trap cavity. The hollowparticulate trap comprises a funnel shaped surface terminating in anopening.

Example 10—The sterile packaging assembly of Example 9, furthercomprising an adhesive positioned inside the hollow particulate trap.

Example 11—The sterile packaging assembly of Examples 9 or 10, whereinthe hollow particulate trap is opaque.

Example 12—The sterile packaging assembly of Examples 9, 10, or 11,wherein the hollow particulate trap is the same color as the tray.

Example 13—The sterile packaging assembly of Examples 9, 10, 11, or 12,wherein the hollow particulate trap further comprises a soundproofingmaterial.

Example 14—The sterile packaging assembly of Examples 9, 10, 11, 12, or13, wherein the hollow particulate trap further comprises another funnelshape surface terminating in another opening.

Example 15—The sterile packaging assembly of Examples 9, 10, 11, 12, 13,or 14, wherein the hollow particulate trap is not visible when thesurgical instrument is positioned in the tray.

Example 16—The sterile packaging assembly of Examples 9, 10, 11, 12, 13,14, or 15, wherein the tray further comprises another trap cavity,wherein the sterile packing assembly further comprises another hollowparticulate trap positionable in the another trap cavity.

Example 17—A sterile packaging assembly comprising a surgicalinstrument, a tray, and a particulate trap. The tray comprises aninstrument cavity configured to receive the surgical instrument, and atrap cavity. The particulate trap is positioned in the trap cavity. Theparticulate trap comprises a funnel shaped surface terminating in anopening. The opening is in communication with a chamber defined in theparticulate trap.

Example 18—The particulate trap of Example 17, further comprising anadhesive positioned in the chamber, wherein the adhesive is configuredto trap particulates thereto.

Example 19—The particulate trap of Examples 17 or 18, wherein theparticulate trap is opaque.

Example 20—The particulate trap of Examples 17, 18, or 19, wherein theparticulate trap further comprises a soundproofing material.

Example Set 9

Example 1—A staple cartridge comprising a cartridge body, a longitudinalslot defined in the cartridge body, and a deck surface positioned on afirst side of the longitudinal slot. The deck surface comprises aplurality of staple cavity openings. The staple cartridge furthercomprises staples removable stored in the staple cavity openings, ahoneycomb extension extending above the deck surface, and a plurality ofthrough holes defined in the honeycomb extension. Each through hole isaligned with a corresponding staple cavity opening. Each through hole islarger than the corresponding staple cavity opening. The through holesare configured to prevent the flow of tissue when the staples areejected from the staple cavity openings during a staple firing stroke.

Example 2—The staple cartridge of Example 1, wherein each staple cavityopening defines a first perimeter, wherein each through hole defines asecond perimeter, and wherein the second perimeter is partially alignedwith the first perimeter.

Example 3—The staple cartridge of Examples 1 or 2, wherein the decksurface comprises a first deck surface, and wherein the staple cartridgefurther comprises a second deck surface positioned below the first decksurface.

Example 4—The staple cartridge of Example 3, wherein the second decksurface comprises a second overall surface area which is smaller than afirst overall surface area of the first deck surface.

Example 5—The staple cartridge of Examples 3 or 4, wherein the seconddeck surface does not surround any of the staple cavity openings.

Example 6—A staple cartridge comprising a cartridge body, a longitudinalslot defined in the cartridge body, and a deck surface positioned on afirst side of the longitudinal slot. The deck surface comprises aplurality of staple cavity openings. The staple cartridge furthercomprises staples removably stored in the staple cavity openings. Thestaple cartridge further comprises a lattice extension extending abovethe deck surface. The lattice extension comprises a plurality of throughholes defined in the lattice extension. Each through hole is alignedwith a corresponding staple cavity opening. Each through hole is largerthan the corresponding staple cavity opening. The through holes areconfigured to prevent the flow of tissue when the staples are fired.

Example 7—The staple cartridge of Example 6, wherein each staple cavityopening defines a first perimeter, wherein each through hole defines asecond perimeter, and wherein the second perimeter is partially alignedwith the first perimeter.

Example 8—The staple cartridge of Examples 6 or 7, wherein the decksurface comprises a first deck surface, and wherein the staple cartridgefurther comprises a second deck surface positioned below the first decksurface.

Example 9—The staple cartridge of Example 8, wherein the second decksurface comprises a second overall surface area which is smaller than afirst overall surface area of the first deck surface.

Example 10—The staple cartridge of Examples 8 or 9, wherein the seconddeck surface does not surround any of the staple cavity openings.

Example 11—A staple cartridge for use with a surgical instrumentincluding an anvil. One of the staple cartridge and the anvil is movablerelative to the other of the staple cartridge and the anvil between anopen position and a closed position. The staple cartridge comprises acartridge body, a longitudinal slot defined in the cartridge body, and astaple cartridge deck defined in the cartridge body. The staplecartridge deck comprises a first deck surface and a second deck surface.The first deck surface comprises a plurality of openings. The firstsurface is positioned a first distance from the anvil when the staplecartridge and the anvil are in the closed position. The second decksurface comprises a plurality of staple cavity openings. The secondsurface is positioned a second distance from the anvil when the staplecartridge and the anvil are in the closed position. The second distanceis greater than the first distance. Each opening of the first surface isaligned with a corresponding staple cavity opening of the secondsurface. The openings of the first surface are larger than the staplecavity openings of the second surface. The openings of the first surfaceare configure to prevent the flow of tissue when the staple cartridge isfired.

Example 12—The staple cartridge of Example 11, wherein the openings ofthe first surface are arranged in a honeycomb pattern.

Example 13—The staple cartridge of Examples 11 or 12, wherein theopenings of the first surface are a different shape than the staplecavity openings of the second surface.

Example 14—The staple cartridge of Examples 11, 12, or 13, wherein thestaple cavity openings of the second surface are the same shape, andwherein the openings of the first surface are a different shape than thesame shape.

Example 15—The staple cartridge of Examples 11, 12, 13, or 14, whereinan opening of the first surface is a different size than another openingof the first surface.

Example 16—The staple cartridge of Examples 11, 12, 13, 14, or 15,wherein an opening of the first surface defines a first shape, whereinanother opening of the first surface defines a second shape, and whereinthe first shape and the second shape are different.

Example 17—The staple cartridge of Examples 11, 12, 13, 14, 15, or 16,further comprising a third deck surface positioned below the first decksurface and the second deck surface.

Example 18—The staple cartridge of Example 17, wherein the third decksurface comprises a second overall surface area which is smaller than anoverall surface area of the second deck surface.

Example 19—The staple cartridge of Examples 17 or 18, wherein the thirddeck surface does not surround any of the openings of the first decksurface or the staple cavity openings of the second deck surface.

Example 20—The staple cartridge of Examples 17, 18, or 19, wherein thefirst deck surface, the second deck surface, and the third deck surfaceare positioned on one side of the longitudinal slot.

Example Set 10

Example 1—A staple cartridge comprising a cartridge body. The cartridgebody comprises a longitudinal slot, a deck surface, and a plurality ofstaple cavities defined in the cartridge body. The cartridge bodyfurther comprises a plurality of cylindrical projections extending fromthe deck surface. The outer diameter of each cylindrical projection isflush with one of a proximal end wall and a distal end wall of eachstaple cavity. The staple cartridge further comprises staples removablystored in the staple cavities.

Example 2—The staple cartridge of Example 1, wherein the cylindricalprojections are not interconnected above the deck surface.

Example 3—The staple cartridge of Examples 1 or 2, wherein eachcylindrical projection comprises an end chamfer.

Example 4—The staple cartridge of Examples 1, 2, or 3, wherein eachcylindrical projection comprises a domed end.

Example 5—A staple cartridge comprising a cartridge body. The cartridgebody comprises a longitudinal slot, a deck surface, and a plurality ofstaple cavities defined in the cartridge body. Each staple cavitycomprises a proximal end wall and a distal end wall. The cartridge bodyfurther comprises a plurality of quarter-sphere projections extendingfrom the deck surface. A face of each quarter-sphere projection is flushwith one of a proximal end wall and a distal end wall of each staplecavity. The staple cartridge further comprises a plurality of staplesstored in the staple cavities.

Example 6—The staple cartridge of Example 5, wherein the plurality ofquarter-sphere projections are not interconnected above the decksurface.

Example 7—The staple cartridge of Examples 5 or 6, wherein the pluralityof quarter-sphere projections extend laterally beyond the staplecavities.

Example 8—A staple cartridge comprising a cartridge body. The cartridgebody comprises a longitudinal slot, a deck surface, and a plurality ofstaple cavities defined in the cartridge body. Each staple cavitycomprises a proximal end wall, a distal end wall, a first lateral sideextending between the proximal end wall and the distal end wall, and asecond lateral side extending between the proximal end wall and thedistal end wall. The second lateral side opposes the first lateral side.The cartridge body further comprises a cylindrical projection extendingfrom the deck surface. The outer diameter of the cylindrical projectionis flush with one of the proximal end wall and the distal end wall. Thecartridge body further comprises a plurality of substantially cubicprojections extending from the deck surface. The plurality of cubicprojections are positioned along the first lateral side and the secondlateral side. Each cubic projection comprises a side that is flush withthe first lateral side or the second lateral side. The staple cartridgefurther comprises a plurality of staples removably stored in the staplecavities.

Example 9—The staple cartridge of Example 8, further comprising gapsbetween the cylindrical projection and the cubic projections.

Example 10—The staple Cartridge of Examples 8 or 9, wherein thecylindrical projection and the cubic projections are not interconnectedabove the deck surface.

Example 11—A staple cartridge comprising a cartridge body. The cartridgebody comprises a longitudinal slot, a deck surface, and a plurality ofstaple cavities defined in the cartridge body. Each staple cavitycomprises a proximal end, a distal end a first lateral side extendingbetween the proximal end and the distal end, and a second lateral sideextending between the proximal end and the distal end. The secondlateral side opposes the first lateral side. The cartridge body furthercomprises a plurality of cylindrical projections extending from the decksurface. The plurality of cylindrical projections are positioned oneither side of each staple cavity at one of the proximal end and thedistal end of each staple cavity. The outer diameter of each cylindricalprojection is flush with either the first lateral side or the secondlateral side of each staple cavity. The staple cartridge furthercomprises staples removably stored in the staple cavities.

Example 12—The staple cartridge of Example 11, wherein the cylindricalprojections are not interconnected above the deck surface.

Example 13—The staple cartridge of Examples 11 or 12, further comprisinggaps between the cylindrical projections.

Example 14—A staple cartridge comprising a cartridge body. The cartridgebody comprises a longitudinal slot, a deck surface, and a plurality ofstaple cavities defined in the cartridge body. Each staple cavitycomprises a proximal end, a distal end, a first lateral side extendingbetween the proximal end and the distal end, and a second lateral sideextending between the proximal end and the distal end. The secondlateral side opposes the first lateral side. The cartridge body furthercomprises a plurality of substantially cubic projections extending fromthe deck surface. The plurality of cubic projections are positioned oneither side of each staple cavity at one of the proximal end and thedistal end of each staple cavity. A face of each cubic projection isflush with either the first lateral side or the second lateral side ofeach staple cavity. The staple cartridge further comprises staplesremovably stored in the staple cavities.

Example 15—The staple cartridge of Example 14, wherein the cubicprojections are not interconnected above the deck surface.

Example 16—A staple cartridge comprising a cartridge body. The cartridgebody comprises a longitudinal slot, a deck surface, and a plurality ofstaple cavities defined in the cartridge body. Each staple cavitycomprises a proximal end including a proximal end wall, a distal endincluding a distal end wall, a first lateral side extending between theproximal end and the distal end, and a second lateral side extendingbetween the proximal end and the distal end. The second lateral sideopposes the first lateral side. The cartridge body further comprises aplurality of substantially cubic projections extending from the decksurface. The plurality of cubic projections are positioned on eitherside of each staple cavity at one of the proximal end and the distal endof each staple cavity. A face of each cubic projection is flush witheither the first lateral side or the second lateral side of each staplecavity. The cubic projections are not interconnected above the decksurface. The cartridge body further comprises a plurality of cylindricalprojections extending from the deck surface. Each cylindrical projectionis positioned at the other of the proximal end and the distal end ofeach staple cavity. The outer diameter of each cylindrical projection isflush with one of the proximal end wall and the distal end wall of eachstaple cavity of the plurality of staple cavities. The cylindricalprojections are not interconnected above the deck surface. The staplecartridge further comprises staples removably stored in the plurality ofstaple cavities.

Example 17—The staple cartridge of Example 16, wherein the cubicprojections and the cylindrical projections are not interconnected abovethe deck surface.

Example 18—A staple cartridge comprising a cartridge body. The cartridgebody comprises a longitudinal slot, a deck surface, and a plurality ofstaple cavities defined in the cartridge body. Each staple cavitycomprises a proximal end, a distal end, a first lateral side extendingbetween the proximal end and the distal end, and a second lateral sideextending between the proximal end and the distal end. The secondlateral side opposes the first lateral side. The cartridge body furthercomprises a plurality of radial fillet projections extending from thedeck surface. The plurality of radial fillet projections are positionedalong the first lateral side and the second lateral side. The radialfillet projections are not interconnected above the deck surface. Thestaple cartridge further comprises a plurality of staples stored in thestaple cavities.

Example 19—The staple cartridge of Example 18, wherein a portion of eachradial fillet projection is flush with one of the first lateral side andthe second lateral side of each staple cavity.

Example 20—The staple cartridge of Examples 18 or 19, wherein the radialfillet projections are positioned at one of the proximal end and thedistal end of each staple cavity.

Example Set 11

Example 1—A surgical instrument comprising a handle, an elongate shaftextending from the handle, and an end effector extending from theelongate shaft. The elongate shaft defines a longitudinal shaft axis.The end effector comprises a first jaw and a second jaw movable relativeto the first jaw between an open position and a closed position. Thesurgical instrument further comprises an articulation joint, amotor-powered articulation system, a motor-powered firing system, aclosure system, a lock solenoid, a power source, and a control unit. Theend effector is rotatably coupled to the elongate shaft about thearticulation joint. The end effector is rotatable about an articulationaxis that is transverse to the longitudinal shaft axis. Themotor-powered articulation system is configured to rotate the endeffector about the articulation axis. The articulation system isoperated in a plurality of states. The plurality of states comprises anactive state where the end effector is being articulated and an inactivestate where the end effector is not being articulated. The motor-poweredfiring system comprises a firing member movable from an unfired positionto a fired position during a firing stroke. The closure system comprisesa closure trigger operably engaged with the end effector. The closuretrigger is actuatable relative to the handle between an unclampedposition where the second jaw is in the open position and a clampedposition where the second jaw is in the closed position. The locksolenoid is movable between an actuated position where the lock solenoidis engaged with a portion of the closure system and an unactuatedposition where the lock solenoid is not engaged with the closure system.The closure system is prevented from being actuated when the locksolenoid is in the actuated position. The power source is configured tosupply power to the articulation system, the firing system, and the locksolenoid. The control unit is configured to control the supply of powerfrom the power source to the articulation system, the firing system, andthe lock solenoid. The control unit moves the lock solenoid to theactuated position and prevents the supply of power from the power sourceto the firing system when the articulation system is in the activestate.

Example 2—The surgical instrument of Example 1, further comprising aclosure sensor in signal communication with the control unit, whereinthe closure sensor is configured to detect when the closure trigger isin the clamped position.

Example 3—The surgical instrument of Examples 1 or 2, wherein thecontrol unit is configured to prevent the supply of power from the powersource to the firing system when the closure trigger is not in theclamped position.

Example 4—The surgical instrument of Examples 1, 2, or 3, wherein one ofthe first jaw and the second jaw is configured to receive a staplecartridge, and wherein the other of the first jaw and the second jawcomprises an anvil.

Example 5—The surgical instrument of Example 4, further comprising thestaple cartridge.

Example 6—A surgical instrument comprising a handle, an elongate shaftextending from the handle and defining a longitudinal shaft axis, an endeffector extending from the elongate shaft, an articulation joint, apowered articulation system, a powered firing system, a closure system,a lock system, a power source, and a control unit. The end effectorcomprises a pair of jaws movable between an open position and a closedposition. The end effector is rotatably coupled to the elongate shaftabout the articulation joint. The end effector is rotatable about anarticulation axis that is transverse to the longitudinal shaft axis. Thepowered articulation system is configured to rotate the end effectorabout the articulation axis. The articulation system is operable in aplurality of states. The plurality of states comprises an active statewhere the end effector is being articulated and an inactive state wherethe end effector is not being articulated. The powered firing systemcomprises a firing member movable from an unfired position to a firedposition during a firing stroke. The closure system comprises a closuretrigger operably engaged with the end effector. The closure trigger isactuatable relative to the handle between an unclamped position wherethe end effector is in the open position and a clamped position wherethe end effector is in the closed position. The lock system is operablein a plurality of states. The plurality of states comprises a lockedstate where the lock system locks the closure system and an unlockedstate where the lock system unlocks the closure system. The closuresystem is prevented from being actuated when the lock system is in thelocked state. The power source is configured to supply power to thearticulation system, the firing system, and the lock system. The controlunit is configured to control the supply of power from the power sourceto the articulation system, the firing system, and the lock system. Thecontrol unit transitions the lock system to the locked state andprevents the supply of power from the power source to the firing systemwhen the articulation system is in the active state.

Example 7—The surgical instrument of Example 6, further comprising aclosure sensor in signal communication with the control unit, whereinthe closure sensor is configured to detect when the closure trigger isin the clamped position.

Example 8—The surgical instrument of Examples 6 or 7, wherein thecontrol unit is configured to prevent the supply of power from the powersource to the firing system when the closure trigger is not in theclamped position.

Example 9—The surgical instrument of Examples 6, 7, or 8, wherein theend effector is configured to receive a staple cartridge.

Example 10—The surgical instrument of Example 9, further comprising thestaple cartridge.

Example 11—A surgical instrument comprising a handle, an elongate shaftextending from the handle and defining a longitudinal shaft axis, an endeffector extending from the elongate shaft, an articulation joint, apower source, a powered articulation system, a closure system, and acontrol unit. The end effector comprises a first jaw and a second jawmovable relative to the first jaw between an open position and a closedposition. The end effector is rotatably coupled to the elongate shaftabout the articulation joint. The end effector is rotatable about anarticulation axis that is transverse to the longitudinal shaft axis. Thepowered articulation system is configured to rotate the end effectorabout the articulation axis when power is supplied from the powersource. The closure system comprises a closure trigger and a closuresensor. The closure trigger is operably engaged with the end effector.The closure trigger is actuatable relative to the handle between anunclamped position where the second jaw is in the open position and aclamped position where the second jaw is in the closed position. Theclosure sensor is configured to detect the position of the closuretrigger. The control unit is configured to control the supply of powerfrom the power source to the articulation system. The closure sensor isin signal communication with the control unit. The control unit preventsthe supply of power from the power source to the articulation systemwhen the closure sensor detects the closure trigger is not in theunclamped position.

Example 12—The surgical instrument of Example 11, further comprising apowered firing system comprises a firing member movable from an unfiredposition to a fired position during a firing stroke, wherein the powersource is configured to supply power to the firing system, and whereinthe control unit is configured to control the supply of power to thefiring system.

Example 13—The surgical instrument of Example 12, wherein the controlunit is configured to prevent the power source from supplying power tothe firing system when the closure trigger is not in the clampedposition.

Example 14—The surgical instrument of Examples 11, 12, or 13, whereinone of the first jaw and the second jaw is configured to receive astaple cartridge, and wherein the other of the first jaw and the secondjaw comprises an anvil.

Example 15—The surgical instrument of Example 14, further comprising thestaple cartridge.

Example 16—A surgical instrument comprising a handle, an elongate shaftextending from the handle and defining a longitudinal shaft axis, an endeffector extending from the elongate shaft, an articulation joint, apower source, a powered articulation system, a motor-powered closuresystem, a closure sensor, and a control unit. The end effector comprisesa first jaw and a second jaw movable relative to the first jaw betweenan open position and a closed position. The end effector is rotatablycoupled to the elongate shaft about the articulation joint. The endeffector is rotatable about an articulation axis that is transverse tothe longitudinal shaft axis. The powered articulation system isconfigured to rotate the end effector about the articulation axis whenpower is supplied from the power source. The motor-powered closuresystem is operably engaged with the end effector. The closure system istransitionable between an unactuated state where the second jaw is inthe open position and an actuated state where the second jaw is in theclosed position. The closure sensor is configured to detect when theclosure system is being actuated. The control unit is configured tocontrol the supply of power from the power source to the articulationsystem. The closure sensor is in signal communication with the controlunit. The control unit prevents the supply of power from the powersource to the articulation system when the closure sensor detects theclosure system is being actuated.

Example 17—The surgical instrument of Example 16, further comprising apowered firing system comprising a firing member movable from an unfiredposition to a fired position during a firing stroke, wherein the powersource is configured to supply power to the firing system, and whereinthe control unit is configured to control the supply of power to thefiring system.

Example 18—The surgical instrument of Example 17, wherein the controlunit is configured to prevent the power source from supplying power tothe firing system when the closure system is being actuated.

Example 19—The surgical instrument of Examples 16, 17, or 18, whereinone of the first jaw and the second jaw is configured to receive astaple cartridge, and wherein the other of the first jaw and the secondjaw comprises an anvil.

Example 20—The surgical instrument of Example 19, further comprising thestaple cartridge.

Example 21—A surgical instrument comprising a handle, an elongate shaftextending from the handle and defining a longitudinal shaft axis, an endeffector extending from the elongate shaft, a shaft rotation system, anda closure system. The end effector comprises a first jaw and a secondjaw movable relative to the first jaw between an open position and aclosed position. The shaft rotation system is operably engaged with theend effector and the elongate shaft. The shaft rotation system istransitionable between a locked state where the end effector and theelongate shaft are prevented from rotating about the shaft axis and anunlocked state where the end effector and the elongate shaft arerotatable about the shaft axis. The closure system is operably engagedwith the end effector and is transitionable between an unactuated statewhere the second jaw is in the open position and an actuated state wherethe second jaw is in the closed position. The closure system transitionsthe shaft rotation system from the unlocked state to the locked statewhen the closure system is actuated.

Example 22—The surgical instrument of Example 21, wherein the shaftrotation system comprises a motor-powered shaft rotation systemconfigured to rotate the end effector and the elongate shaft about theshaft axis when power is supplied from a power source to themotor-powered shaft rotation system.

Example 23—The surgical instrument of Example 22, further comprising acontrol unit and a closure sensor in signal communication with thecontrol unit, wherein the closure sensor is configured to detect whenthe closure system is being actuated, and wherein the control unitprevents the supply of power from the power source to the motor-poweredshaft rotation system when the closure sensor detects the closure systemis being actuated.

Many of the surgical instrument systems described herein are motivatedby an electric motor; however, the surgical instrument systems describedherein can be motivated in any suitable manner. In various instances,the surgical instrument systems described herein can be motivated by amanually-operated trigger, for example. In certain instances, the motorsdisclosed herein may comprise a portion or portions of a roboticallycontrolled system. Moreover, any of the end effectors and/or toolassemblies disclosed herein can be utilized with a robotic surgicalinstrument system. U.S. patent application Ser. No. 13/118,241, entitledSURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENTARRANGEMENTS, now U.S. Pat. No. 9,072,535, for example, disclosesseveral examples of a robotic surgical instrument system in greaterdetail and is incorporated by reference herein in its entirety.

The surgical instrument systems described herein have been described inconnection with the deployment and deformation of staples; however, theembodiments described herein are not so limited. Various embodiments areenvisioned which deploy fasteners other than staples, such as clamps ortacks, for example. Moreover, various embodiments are envisioned whichutilize any suitable means for sealing tissue. For instance, an endeffector in accordance with various embodiments can comprise electrodesconfigured to heat and seal the tissue. Also, for instance, an endeffector in accordance with certain embodiments can apply vibrationalenergy to seal the tissue.

The entire disclosures of:

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U.S. patent application Ser. No. 13/800,067, entitled STAPLE CARTRIDGETISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, now U.S. PatentApplication Publication No. 2014/0263552;

U.S. Patent Application Publication No. 2007/0175955, entitled SURGICALCUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER LOCKING MECHANISM,filed Jan. 31, 2006; and

U.S. Patent Application Publication No. 2010/0264194, entitled SURGICALSTAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR, filed Apr. 22,2010, now U.S. Pat. No. 8,308,040, are hereby incorporated by referenceherein.

Although various devices have been described herein in connection withcertain embodiments, modifications and variations to those embodimentsmay be implemented. Particular features, structures, or characteristicsmay be combined in any suitable manner in one or more embodiments. Thus,the particular features, structures, or characteristics illustrated ordescribed in connection with one embodiment may be combined in whole orin part, with the features, structures or characteristics of one oremore other embodiments without limitation. Also, where materials aredisclosed for certain components, other materials may be used.Furthermore, according to various embodiments, a single component may bereplaced by multiple components, and multiple components may be replacedby a single component, to perform a given function or functions. Theforegoing description and following claims are intended to cover allsuch modification and variations.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, a device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the stepsincluding, but not limited to, the disassembly of the device, followedby cleaning or replacement of particular pieces of the device, andsubsequent reassembly of the device. In particular, a reconditioningfacility and/or surgical team can disassemble a device and, aftercleaning and/or replacing particular parts of the device, the device canbe reassembled for subsequent use. Those skilled in the art willappreciate that reconditioning of a device can utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

The devices disclosed herein may be processed before surgery. First, anew or used instrument may be obtained and, when necessary, cleaned. Theinstrument may then be sterilized. In one sterilization technique, theinstrument is placed in a closed and sealed container, such as a plasticor TYVEK bag. The container and instrument may then be placed in a fieldof radiation that can penetrate the container, such as gamma radiation,x-rays, and/or high-energy electrons. The radiation may kill bacteria onthe instrument and in the container. The sterilized instrument may thenbe stored in the sterile container. The sealed container may keep theinstrument sterile until it is opened in a medical facility. A devicemay also be sterilized using any other technique known in the art,including but not limited to beta radiation, gamma radiation, ethyleneoxide, plasma peroxide, and/or steam.

While this invention has been described as having exemplary designs, thepresent invention may be further modified within the spirit and scope ofthe disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the invention using its generalprinciples.

What is claimed is:
 1. A sterile packaging assembly configured toreceive a surgical instrument, wherein the sterile packaging assemblycomprises: a vacuum-molded tray, comprising: an instrument cavityconfigured to receive the surgical instrument; and a trap cavity; and aparticulate trap positioned in said trap cavity, wherein saidparticulate trap comprises a housing including a funnel shaped sidewallterminating in an opening, wherein said opening is in communication witha chamber defined in said particulate trap, wherein said funnel shapedsidewall defines a concave surface on an outside portion of saidhousing, and wherein said funnel shape sidewall defines a convex surfacewithin said chamber.
 2. The sterile packaging assembly of claim 1,wherein said particulate trap is opaque.
 3. The sterile packagingassembly of claim 1, wherein said particulate trap is the same color assaid vacuum-molded tray.
 4. The sterile packaging assembly of claim 1,wherein said particulate trap further comprises a soundproofingmaterial.
 5. The sterile packaging assembly of claim 1, wherein saidhousing comprises another funnel shaped side terminating in anotheropening in communication with said chamber.
 6. The sterile packagingassembly of claim 1, wherein said vacuum-molded tray comprises anothertrap cavity, wherein said sterile packing assembly comprises anotherparticulate trap positioned in said another trap cavity.
 7. A sterilepackaging assembly configured to receive a surgical instrument, whereinthe sterile packaging assembly comprises: a vacuum-molded tray,comprising: an instrument cavity configured to receive the surgicalinstrument; and a trap cavity; and a particulate trap positioned in saidtrap cavity, wherein said particulate trap comprises a housing includinga funnel shaped side terminating in an opening, wherein said opening isin communication with a chamber defined in said particulate trap, andwherein said particulate trap further comprises an adhesive positionedin said chamber.
 8. A sterile packaging assembly configured to receive asurgical instrument, wherein the sterile packaging assembly comprises: avacuum-molded tray, comprising: an instrument cavity configured toreceive the surgical instrument; and a trap cavity; and a particulatetrap positioned in said trap cavity, wherein said particulate trapcomprises a housing including a funnel shaped side terminating in anopening, wherein said opening is in communication with a chamber definedin said particulate trap, and wherein said particulate trap is notvisible when the surgical instrument is positioned in said sterilepackaging assembly.
 9. A sterile packaging assembly configured toreceive a surgical instrument, wherein the sterile packaging assemblycomprises: a tray, comprising: an instrument cavity configured toreceive the surgical instrument; and a trap cavity; and a hollowparticulate trap positioned in said trap cavity, wherein said hollowparticulate trap comprises a wall comprising an opening, a first side,and a second side opposite said first side, wherein said opening is incommunication with a chamber defined in said hollow particulate trap,wherein said first side of said wall defines a concave surface on anoutside portion of said hollow particulate trap, and wherein said secondside of said wall defines a convex surface within said chamber.
 10. Thesterile packaging assembly of claim 9, wherein said hollow particulatetrap is opaque.
 11. The sterile packaging assembly of claim 9, whereinsaid hollow particulate trap is the same color as said tray.
 12. Thesterile packaging assembly of claim 9, wherein said hollow particulatetrap further comprises a soundproofing material.
 13. The sterilepackaging assembly of claim 9, wherein said hollow particulate trapfurther comprises another funnel shape surface terminating in anotheropening.
 14. The sterile packaging assembly of claim 9, wherein saidtray further comprises another trap cavity, wherein said sterile packingassembly further comprises another hollow particulate trap positionablein said another trap cavity.
 15. A sterile packaging assembly configuredto receive a surgical instrument, wherein the sterile packaging assemblycomprises: a tray, comprising: an instrument cavity configured toreceive the surgical instrument; and a trap cavity; a hollow particulatetrap positioned in said trap cavity, wherein said hollow particulatetrap comprises a funnel shaped surface terminating in an opening; and anadhesive positioned inside said hollow particulate trap.
 16. A sterilepackaging assembly configured to receive a surgical instrument, whereinthe sterile packaging assembly comprises: a tray, comprising: aninstrument cavity configured to receive the surgical instrument; and atrap cavity; and a hollow particulate trap positioned in said trapcavity, wherein said hollow particulate trap comprises a funnel shapedsurface terminating in an opening, and wherein said hollow particulatetrap is not visible when the surgical instrument is positioned in saidtray.
 17. A sterile packaging assembly, comprising: a surgicalinstrument; a tray, comprising: an instrument cavity configured toreceive the surgical instrument; and a trap cavity; and a particulatetrap positioned in said trap cavity, wherein said particulate trapcomprises a funnel shaped wall terminating in an opening, wherein saidopening is in communication with a chamber defined in said particulatetrap, wherein said funnel shaped wall defines a concave surface on anoutside portion of said particulate trap, and wherein said funnel shapewall defines a convex surface within said chamber.
 18. The particulatetrap of claim 17, wherein said particulate trap is opaque.
 19. Theparticulate trap of claim 17, wherein said particulate trap furthercomprises a soundproofing material.
 20. A sterile packaging assembly,comprising: a surgical instrument; a tray, comprising: an instrumentcavity configured to receive the surgical instrument; and a trap cavity;a particulate trap positioned in said trap cavity, wherein saidparticulate trap comprises a funnel shaped surface terminating in anopening, and wherein said opening is in communication with a chamberdefined in said particulate trap; and an adhesive positioned in saidchamber, wherein said adhesive is configured to trap particulatesthereto.